Operation, Maintenance, and Parts Manual
TUG Technologies Corporation
•
815 Allgood Rd., Marietta, GA 30062
MODEL
TR/TMD-150/180/250
AIR START UNIT
Aircraft Ground Support Equipment
CD295
Front Matter
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RECORD OF REVISIONS
Property of:
Company:
Address:
City:
State:
Country:
Postal Code:
REVISION DATA
CHECK EACH REVISION RECEIVED AND INSERT THE REVISED AND
SUPPLEMENTARY PAGES IN YOUR MANUAL.
DATE OF ORIGINAL PUBLICATION: APRIL 2000
REVISION
DATE
1
September 2000
2
February 2001
3
March 2002
4
July 2002
5
October 2005
6
December 2005
7
8
9
10
CD295
i
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Front Matter
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LIST OF EFFECTIVE PAGES
TR/TDM-150/180/250
Record of Revisions - i
List of Effective Pages - ii, iii
Manual TOC - iv thru viii
List of Figures - ix thru xi
List of Tables - xii thru xiv
Introduction - xv
Unit Identification - xv
Technical Assistance - xvi
Safety Precautions - xvii
How to Use this Manual - xviii
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CHAPTER 1
1-TOC-i thru 1-TOC-ii
1-1-1
1-1-2
1-1-3 thru 1-1-7
1-1-8
1-1-9
1-1-10 thru 1-1-11
1-1-12
1-2-1 thru 1-2-3
1-2-4 thru 1-2-10
1-2-11
1-2-12 thru 1-2-13
1-2-14
1-3-1
1-3-2
1-3-3 thru 1-3-4
1-3-5
1-3-6
1-4-1 thru 1-4-4
1-5-1 thru 1-5-4
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CHAPTER 2
2-TOC-i thru 2-TOC-ii
2-1-1 thru 2-1-4
2-2-1 thru 2-2-2
2-2-3
2-2-4
2-2-5
2-2-6
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2-2-7
2-2-8
2-2-9
2-2-10
2-2-11
2-2-12 thru 2-2-15
2-2-16
2-2-17
2-2-18
2-2-19
2-2-20
2-3-1
2-3-2
2-3-3
2-3-4 thru 2-3-22
2-3-23
2-3-24
2-3-25 thru 2-3-26
2-3-27 thru 2-3-36
2-3-37
2-3-38
2-3-39
2-3-40 thru 2-3-41
2-3-42
2-3-43 thru 2-3-45
2-3-46
2-3-47 thru 2-3-49
2-3-50 thru 2-3-57
2-3-58
2-3-59 thru 2-3-60
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CHAPTER 3
3-TOC-i thru 3-TOC-ii
3-1-1
3-1-2
3-2-1
3-2-2
3-2-3
3-2-4 thru 3-2-7
3-2-8
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CD295
Front Matter
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LIST OF EFFECTIVE PAGES (CONT.)
CD295
CHAPTER 4
4-TOC-i thru 4-TOC-ii
4-1-1
4-1-2
4-1-3
4-1-4
4-2-1
4-2-2
4-3-1 thru 4-3-14
4-4-1 thru 4-4-2
4-4-1-1 thru 4-4-1-12
4-4-1-13
4-4-1-14 thru 4-4-1-16
4-4-2-1 thru 4-4-2-2
4-4-3-1 thru 4-4-3-4
4-4-3-5
4-4-3-6
4-4-3-7
4-4-3-8
4-4-4-1 thru 4-4-4-4
4-4-5-1 thru 4-4-5-4
4-4-6-1 thru 4-4-6-5
4-4-6-6 thru 4-4-6-7
4-4-6-8
4-4-7-1 thru 4-4-7-4
4-4-8-1
4-4-8-2
4-4-8-3
4-4-8-4
4-4-8-5
4-4-8-6 thru 4-4-8-33
4-4-8-34 thru 4-4-8-35
4-4-8-36
4-4-9-1 thru 4-4-9-2
4-4-9-3
4-4-9-4
4-4-10-1 thru 4-4-10-10
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CHAPTER 5
5-TOC-i thru 5-TOC-ii
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CHAPTER 6
6-TOC-i thru 6-TOC-iv
6-1-1 thru 6-1-2
6-1-3 thru 6-1-6
6-2-1 thru 6-2-2
6-3-1 thru 6-3-4
6-4-1 thru 6-4-4
6-5-1 thru 6-5-2
6-6-1 thru 6-6-2
6-7-1 thru 6-7-2
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Front Matter
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MANUAL TABLE OF CONTENTS
DESCRIPTION
CHAPTER-SECTION-PAGE
Title Page
Record of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/i
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/ii
Manual Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/iv
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/ix
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xii
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xv
Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xv
Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xvi
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xvii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Matter/xviii
Chapter 1 General Information & Operating Instructions
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-TOC-i
Section 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.2 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.3 Engine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2
1.4 Air Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2
1.5 Air Regulation System Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-4
1.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-4
1.7 Electrical Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-8
1.8 Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-8
1.9 Automatic Shutdown Protective Circuit . . . . . . . . . . . . . . . . . . . . . . . 1-1-9
1.10 Normal Shutdown Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-10
1.11 Emergency Shutdown Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-11
1.12 Miscellaneous Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-11
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
2.1 Pre-Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
2.2 Starting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2
2.3 Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
2.4 Engine Protective Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
2.5 Air Start Unit Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
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MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION
CHAPTER-SECTION-PAGE
Chapter 1 General Information & Operating Instructions (Cont.)
Section 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
3.2 Specification Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
Section 4 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.2 Tie-Down Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.3 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.4 Preparing the Engine and Compressor . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.5 Preparing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
4.6 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
4.7 Receiving Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
4.8 Preparing Unit for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
Section 5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
5.1 Preparing Unit for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
5.2 Temporary Storage (30 days or less) . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
5.3 Extended Storage (more than 30 days) . . . . . . . . . . . . . . . . . . . . . . . 1-5-2
5.4 Restoring a Unit from Extended Storage . . . . . . . . . . . . . . . . . . . . . . 1-5-4
Chapter 2 Maintenance
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-TOC-i
Section 1 Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 2-1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
1.2 How to Use the Preventive Maintenance Schedule . . . . . . . . . . . . . . . 2-1-1
Section 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
2.2 How to Use the Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
2.3 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2
2.4 Special Tools & Equipment (Engine Troubleshooting) . . . . . . . . . . . . . 2-2-3
2.5 Compressor and Air Pressure Regulation System Troubleshooting . . 2-2-10
2.6 Special Tools & Equipment (Compressor Troubleshooting) . . . . . . . . 2-2-11
2.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
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MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION
CHAPTER-SECTION-PAGE
Chapter 2 Maintenance (Cont.)
Section 2 Troubleshooting (Cont.)
2.8 Special Tools & Equipment (Electrical Troubleshooting) . . . . . . . . . . 2-2-15
2.9 Electrical Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
2.10 Trailer Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
2.11 Special Tools & Equipment (Trailer Chassis Troubleshooting) . . . . . . 2-2-19
Section 3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1
3.2 How to Use the Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . 2-3-2
3.3 List of Effective Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . 2-3-3
Chapter 3 Overhaul
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-TOC-i
Section 1 Overhaul Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
1.1 Air Start Unit Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
1.3 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .‘3-1-1
Section 2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
2.2 Preparation for Engine/Compressor Removal . . . . . . . . . . . . . . . . . . . 3-2-1
2.3 Engine/Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2
2.4 Engine/Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2
2.5 Installation and Reconnection of Other Equipment . . . . . . . . . . . . . . . 3-2-3
2.6 Removal of Air Start Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . 3-2-4
2.7 Installation of Air Start Pressure Regulator . . . . . . . . . . . . . . . . . . . . 3-2-4
2.8 Removal and Replacement of Air Solenoid Valves . . . . . . . . . . . . . . . 3-2-5
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MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION
CHAPTER-SECTION-PAGE
Chapter 4 Illustrated Parts Breakdown
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-TOC-i
Section 1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
1.2 Using the Illustrated Parts List (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
1.3 How to Locate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
1.4 How to Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
Section 2 Manufacturer’s Identification . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1
Section 3 Alphanumeric Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1
Section 4
Group Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1
Chapter 5 Drawings
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-TOC-i
Chapter 6 Optional Equipment and Manufacturer’s Data
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-TOC-i
Option 1 Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
1.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Option 2
2.1
2.2
2.3
TR/TMD-150/180/250 Air Start Unit,
Low Fuel Level in Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Option 3 Air Delivery Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
3.2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
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MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION
CHAPTER-SECTION-PAGE
Chapter 6 Optional Equipment and Manufacturer’s Data (Cont.)
Option 4 Engine Running Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
4.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
Option 5 Jet Start Mode Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
5.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Option 6 Engine Warm-Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
6.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
Option 7 Counter and Label-Emergency Stop . . . . . . . . . . . . . . . . . . . 6-7-1
7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
7.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
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Front Matter
AIR START UNIT
LIST OF FIGURES
CHAPTER/ TITLE
FIGURE
PAGE
Chapter 1 General Information & Operating Instructions
1.1
Model TMD-150/180/250 Air Start Unit
1-1-1
1.2
Schematic, Lube Oil GHH Compressors
1-1-4
1.3
Dual Pressure Air Regulation System
1-1-5 & 1-1-6
1.4
Control Panel
1-2-6, -8, -10, -12
Chapter 2 Maintenance
MI 02005A
Fig. 1
Hub and Drum Assembly
MI 03001A
Fig. 1
Fig. 2
Parking Brake Adjustment
Brake Shoe Adjustment
2-3-17
2-3-18
MI 04004A
Fig. 1
Fuel Filter/Water Separator (Option)
2-3-22
MI 04005A
Fig. 1
Fuel Filter/Water Separator (Option)
2-3-24
MI 06002A
Fig. 1
Engine Oil Component Assembly
2-3-26
MI 08003A
Fig. 1
Fig. 2
Engine Air Cleaner Assembly
Compressor Air Cleaner Assembly
2-3-32
2-3-33
MI 11001A
Fig. 1
Unloader Valve
2-3-36
MI 11002A
Fig. 1
Fig. 2
Compressor Oil Component Assembly
Compressor Fluid Level and Fill Locations
2-3-41
2-3-42
Regulator/Solenoid Assembly,
Typical Jet Start/Air Packs
2-3-46
MI 11020A
Fig. 1
Compressor Air Safety Valve
2-3-49
MI 99002A
Fig. 1
Fig. 2
Fluid Level and Fill Locations
Diesel Fuel Specifications
2-3-53
2-3-54
MI 11019A
Fig. 1
CD295
2-3-14
ix
Rev 6
Front Matter
AIR START UNIT
LIST OF FIGURES (CONT.)
CHAPTER/ TITLE
FIGURE
Chapter 2 Maintenance (Cont.)
MI 11020A
Fig. 1
Compressor Discharge Coupling
Chapter 3 Overhaul
3.1
Regulator/Solenoid Assembly,
Typical Jet Start/Air Packs
Chapter 4 Illustrated Parts Breakdown
Group 1
1.1
TMD-150/180/250 Overall Assembly
1.2
TMD-150/180/250 Overall Rear Axle Assembly
1.3
Fifth Wheel Hub Assemblies
1.4
Overall Axle Assembly
1.5
Brake Assembly
1.6
Door Assembly
1.7
Hose Basket Parts Assembly
x
Rev 6
PAGE
2-3-60
3-2-5 & 3-2-7
4-4-1-2
4-4-1-4
4-4-1-6
4-4-1-8
4-4-1-10
4-4-1-12
4-4-1-14
Group 3
3.1
3.2
Standard Fuel Kit Assembly
Standard Fuel with Manual Prime Pump Option
4-4-3-2
4-4-3-4
Group 4
4.1
Engine Air Intake Assembly
4-4-4-2
Group 6
6.1
6.2
6.3
Fan Drive Parts Assembly
Jacket Water Parts Assembly
Charge Air Cooler Parts Assembly
4-4-6-2
4-4-6-4
4-4-6-6
Group 7
7.1
Engine Exhaust Parts Assembly
4-4-7-2
Group 8
8.1
8.2
Control Panel, Assembly
Control Panel, Assembly, Main Relay Panel
4-4-8-2, -4
4-4-8-6, -8
CD295
Front Matter
AIR START UNIT
LIST OF FIGURES (CONT.)
CHAPTER/ TITLE
FIGURE
PAGE
Chapter 4 Illustrated Parts Breakdown (Cont.)
Group 8 (Cont.)
8.3
Compressor, Fuel Tank, and Skid
Electrical Components
8.4
Engine Electrical Components
8.5
Engine ECM and Fuse Box
8.6
Battery Parts Assembly
Group 9
9.1
Lube Oil GHH Compressors
Group 10
10.1
10.2
10.3
Discharge/Unloader Parts Assembly
Unloader Valve Assembly
Compressor Air Cleaner Assembly
4-4-8-12, -16, -20
4-4-8-24, -28
4-4-8-32
4-4-8-34
4-4-9-2
4-4-10-2, -4
4-4-10-6
4-4-10-8
Chapter 5 Drawings
See the applicable drawings.
Chapter 6 Optional Equipment and Manufacturer’s Data
Option 1
1.1
Standard Fuel Kit Assembly with Racor Filter Option
CD295
6-1-2
Option 3
3.1
Air Delivery Hoses
6-3-2
Option 4
4.1
Engine Running Beacon
6-4-2
xi
Rev 6
Front Matter
AIR START UNIT
LIST OF TABLES
CHAPTER/ TITLE
TABLE
Chapter 1 General Information and Operating Instructions
1.1
Normal Operating Conditions
1.2
Controls and Indicators
1.3
Specifications Standard Detroit Diesel
TR/TMD-150 Air Start Unit
1.4
Specifications Standard Detroit Diesel
TR/TMD-180 Air Start Unit
1.5
Specifications Standard Detroit Diesel
TR/TMD-250 Air Start Unit
1.6
Fuel Capacities, TR/TMD-150/180/250
Chapter 2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
Maintenance
Preventive Maintenance Schedule
Engine Will Not Crank
Engine Cranks, But Will Not Start
Engine Starts, But Will Not Continue to Run
Malfunction Shutdowns
Abnormal Operation
Compressor High Discharge Air Temperature
Compressor Low Discharge Air Pressure in Jet Start
or Air Condition Mode
Compressor High Discharge Air Pressure in Jet Start
or Air Condition Mode
Compressor Malfunction Indicated
Compressor Oil Leaks
Compressor Discharge Manifold Safety Valve Opens
Starting System Malfunctions
Battery Charging System Malfunctions
Towing Difficulties
Parking Brake Will Not Hold
List of Effective Maintenance Instructions
Chapter 4 Illustrated Parts Breakdown
4.1
Example, Parts List
4.2
Manufacturers Identification
4.3
Alphanumeric Index
xii
Rev 6
PAGE
1-2-5
1-2-7
1-3-1
1-3-2
1-3-4
1-3-5
2-1-2
2-2-3
2-2-4
2-2-6
2-2-6
2-2-8
2-2-11
2-2-12
2-2-13
2-2-13
2-2-14
2-2-14
2-2-16
2-2-18
2-2-19
2-2-20
2-3-3
4-1-1
4-2-1
4-3-1
CD295
Front Matter
AIR START UNIT
LIST OF TABLES (CONT.)
CHAPTER/ TITLE
TABLE
PAGE
Chapter 4 Illustrated Parts Breakdown (Cont.)
Group 1
1.1
TMD-150/180/250 Overall Assembly
1.2
TMD-150/180/250 Overall Rear Axle Assembly
1.3
Fifth Wheel Hub Assemblies
1.4
Overall Axle Assembly
1.5
Brake Assembly
1.6
Door Assembly
1.7
Hose Basket Parts Assembly
Group 2
2.1
Engine Assembly, TR/TMD-150/180/250
4-4-2-2
Group 3
3.1
3.2
Standard Fuel Kit Assembly
Standard Fuel with Manual Prime Pump Option
4-4-3-3
4-4-3-5
Group 4
4.1
Engine Air Intake Assembly
4-4-4-3
Group 6
6.1
6.2
6.3
Fan Drive Parts Assembly
Jacket Water Parts Assembly
Charge Air Cooler Parts Assembly
4-4-6-3
4-4-6-5
4-4-6-7
Group 7
7.1
Engine Exhaust Parts Assembly
4-4-7-3
Group 8
8.1
8.2
8.3
8.4
8.5
8.6
Group 9
9.1
CD295
4-4-1-3
4-4-1-5
4-4-1-7
4-4-1-9
4-4-1-11
4-4-1-13
4-4-1-15
Control Panel, Assembly
Control Panel, Assembly, Main Relay Panel
Compressor, Fuel Tank, and Skid
Electrical Components
Engine Electrical Components
Engine ECM and Fuse Box
Battery Parts Assembly
Lube Oil GHH Compressors
4-4-8-3, -5
4-4-8-7, -9
4-4-8-13, -17, -21
4-4-8-25, -29
4-4-8-33
4-4-8-35
4-4-9-3
xiii
Rev 6
Front Matter
AIR START UNIT
LIST OF TABLES (CONT.)
CHAPTER/ TITLE
TABLE
Chapter 4 Illustrated Parts Breakdown (Cont.)
Group 10
10.1
Discharge/Unloader Parts Assembly
10.2
Unloader Valve Assembly
10.3
Compressor Air Cleaner Assembly
Chapter 6 Optional Equipment and Manufacturer’s Data
Option 1
1.1
Standard Fuel Kit Assembly with Racor Filter Option
Option 2
2.1
xiv
Rev 6
PAGE
4-4-10-3, -5
4-4-10-7
4-4-10-9
6-1-3
TR/TMD-150/180/250 Air Start Unit,
Low Fuel Level in Fuel Tank
6-2-2
Option 3
3.1
Air Delivery Hoses
6-3-3
Option 4
4.1
Engine Running Beacon
6-4-3
Option 5
5.1
Jet Start Timer Light Option
6-5-2
Option 6
6.1
Engine Warm-Up Circuit
6-6-2
Option 7
7.1
Counter and Label Emergency Stop Option
6-7-2
CD295
Front Matter
AIR START UNIT
INTRODUCTION
This manual contains instructions for the overhaul, maintenance, and operation of the
Air Start Unit, Model TR/TMD-150/180/250.
Full benefit of the long life and dependability built into these units can be realized
through proper operation and maintenance. Of equal importance is the use of proper
tools and procedures during equipment overhaul.
Personnel responsible for operation and maintenance should study the sections of the
manual pertaining to their particular duties. Similarly, before beginning a repair or
overhaul job, the service technician should read the manual carefully to become familiar
with the components, parts, or subassemblies of the equipment.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG Technologies Corp.
identification nameplate is located on the operator's compartment of the unit.
MODEL
NUMBER
SERIAL
NUMBER
WORK
ORDER
NUMBER
DATE
OF
MFR
G.V.W.
REFER TO SERIAL NO. WHEN REQUESTING SERVICE
The serial number identification of each unit will appear on the nameplate (as shown
above) along with the work order and date of manufacture. The mailing address of TUG
Technologies Corporation, telephone number, and fax information are all located on the
bottom of the nameplate. This necessary information will ensure the customer a fast and
accurate response to any parts and/or service request.
The aforementioned serial number may pertain to a corresponding alpha code designation used in the parts portion of this book. These letter designations (alpha codes) will
notify customers of any change made to the unit and will be referenced directly to the
unit serial number located on the identification name plate. If the “Usable On Code”
column located in the parts section has been left blank or not referenced with an alpha
code designation, the parts apply to all units.
CD295
xv
Rev 6
Front Matter
AIR START UNIT
TECHNICAL ASSISTANCE
In case of emergency, wire or write:
TUG Technologies Corporation
815 Allgood Road
Marietta, Georgia 30062
Be sure to list the equipment model number, rating, specific nature of the problem, and
the suspected area of malfunction.
For emergency assistance, call:
For Airline Parts: 800-989-8499
(Georgia Residents: 770-422-8021)
For Airline Service: 800-989-8499; TUG Warranty Department
(Georgia Residents: 770-422-7230; ask for Warranty Department.)
xvi
Rev 6
CD295
Front Matter
AIR START UNIT
SAFETY PRECAUTIONS
Observe the safety precautions herein during all phases of operation:
1.
Ensure that the parking brake is set whenever the unit is parked.
2.
Clean or service the unit only with the engine shut down.
3.
To prevent damaging the equipment or setting it up to deteriorate, use only an
approved solvent to clean it.
4.
Do not smoke or use an open flame in the vicinity of any fueling operation.
5.
Prior to starting the unit, ensure that no loose bars, tools, parts, etc., are lying in or
on it. Loose articles can become projectiles that seriously injure personnel or cause
equipment damage.
6.
Pipe exhaust fumes outside of any enclosed operating area.
7.
Properly maintain the equipment by following the manufacturer's recommendations.
8.
In case of a malfunction that shuts down the equipment, do not attempt to restart it
until the cause of the trouble has been corrected. Serious damage to the equipment
can otherwise result.
9.
In case of an accident, immediately shut down the unit.
10.
Before personnel attempt access underneath the unit, ensure it is safely supported
on blocks or other appropriate supporting devices. Ensure that equipment used to
raise and support the air start unit is rated to withstand 150% (1-1/2 times) of the
unit's gross weight.
11.
This equipment uses both metric and S.A.E. (inch-type) fasteners and fittings. This
can present special servicing requirements. Many metric nuts, bolts, and screws are
dimensionally very close to S.A.E.-rated nuts, bolts, and screws. It is easy to
mismatch threads or use improperly sized components. This can result in damage,
malfunction, or possible personal injury. Save components and hardware from the
unit for reuse when possible. If the parts are not reusable, take care to select a
replacement that matches the original in dimensions, strength, and thread pitch.
CD295
xvii
Rev 6
Front Matter
AIR START UNIT
HOW TO USE THIS MANUAL
1.
This manual is divided into six chapters. Each chapter is further subdivided into
applicable sections. See the Table of Contents at the front of each chapter for
details of the contents of that respective chapter.
2.
The page numbering system utilizes a three-part number. The explanation is as
follows:
Section
Number
Chapter
Number
Date of the page’s
latest revision or
“ORIG” if the
original issue.
3.
2-3-4
ORIG
Sequential page
number within a
section.
Warnings, Cautions, and Notes are used throughout this manual. The forms and
explanations are as follows:
Refers to Potential Danger to Personnel.
Refers to Potential Damage to Equipment or Components.
Note:
4.
xviii
Rev 6
Calls attention to methods which make the job easier or to operating procedures, conditions, etc., to be highlighted. Notes appear before or after the
related text, whichever is more logical.
Chapter 6, Options and Manufacturer's Data, is divided into sections. When applicable, each section will contain one particular option. Refer to the Table of
Contents for Chapter 6 for a list of the options. Any information on adjustments,
operation, or maintenance contained in the options section supersedes related
information in the first five chapters of the manual. Additional or new drawings
and schematics required for some options will also be located in Chapter 6 in their
applicable sections. However, Chapter 5 always contains those drawings and
schematics common to all units. Please check the Table of Contents in Chapter 6
against your unit to see what options might be applicable.
CD295
Chapter 1
TOC
Chapter 1
General Information and Operating Instructions
TABLE OF CONTENTS
Section/
Description
Paragraph
Page
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
Engine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2
Air Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2
Air Regulation System Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-4
Electrical Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-8
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-8
Automatic Shutdown Protective Circuit . . . . . . . . . . . . . . . . . . . . . . . 1-1-9
Normal Shutdown Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-10
Emergency Shutdown Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-11
Miscellaneous Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-11
2
2.1
2.2
2.3
2.4
2.5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
Pre-Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
Starting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2
Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Engine Protective Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Air Start Unit Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
3
3.1
3.2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
Specification Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
4
4.1
4.2
4.3
4.4
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
Tie-Down Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
Preparing the Engine and Compressor . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
CD295
4327
1-TOC-i
Orig
Chapter 1
TOC
TABLE OF CONTENTS (CONT.)
Section/
Description
Paragraph
Page
4
4.5
4.6
4.7
4.8
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
Preparing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
Receiving Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
Preparing Unit for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
5
5.1
5.2
5.3
5.4
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
Preparing Unit for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
Temporary Storage (30 days or less) . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
Extended Storage (more than 30 days) . . . . . . . . . . . . . . . . . . . . . . . 1-5-2
Restoring a Unit from Extended Storage . . . . . . . . . . . . . . . . . . . . . . 1-5-4
1-TOC-ii
Orig
CD295
4327
Chapter 1
Section 1
Chapter 1, Section 1
General Description
Figure 1.1
1.1
INTRODUCTION
1.1.1
1.2
Model TMD-150/180/250 Air Start Unit
This manual contains General Specifications, Controls and Indicators, Operating
Instructions, Service Requirements, and Parts Information on the TUG Technologies Corporation Model TR/TMD-150/180/250 Air Start Unit.
UNIT DESCRIPTION
1.2.1
CD295
The Model TMD-150/180/250 (Figure 1.1) air start unit is a self-contained,
weatherproof, diesel-driven power pack. It is provided with all the instruments,
controls, and accessories necessary for the safe and efficient operation of the air
compressor. This unit is trailer mounted, designed to be pulled behind a tow
tractor. See Chapter 6 for details of options.
1-1-1
Rev 6
Chapter 1
Section 1
1.3
1.4
1-1-2
Rev 2
1.2.2
This unit is also designed to be mounted on a truck and with this option, has the
designation TRD-150/180/250. See Chapter 6 for details of this option.
1.2.3
Units are shipped factory adjusted to deliver a maximum of 42 psig (250 kPa) air
for jet start applications, and a maximum of 30 psig (207kPa) air for air packs
mode.
ENGINE DESCRIPTION
1.3.1
The engines are normally equipped with an oil cooler, lubricating oil filter(s),
fuel oil strainer, fuel oil filter, air cleaner, electronic control module (ECM), fan
and radiator, and starting motor.
1.3.2
Fuel System. Fuel is drawn from the supply tank through a primary filter by a
gear-type fuel pump. It is then forced through a secondary filter and into the fuel
inlet manifolds in the cylinder heads and to the injectors. Excess fuel is returned
to the supply tank through the fuel outlet manifolds and connecting lines. Since
fuel is constantly circulating through the injectors, it serves to cool the injectors
and carry off any air in the fuel system.
1.3.3
Air Intake System. Air for scavenging and combustion is supplied by a charge
air manifold which pumps air into the engine cylinders. All air entering the
charge air manifold first passes through an air cleaner and a charge air cooler
(heat exchanger).
1.3.4
Lubrication System. Full pressure lubrication is supplied to all main, connecting
rod, and camshaft bearings, and to other moving parts of the engine. A gear-type
pump draws oil from the oil pan through an intake screen, through the oil filter,
and then to the oil cooler. From the oil cooler, the oil flows through passages that
connect with the oil galleys in the cylinder block and cylinder heads for distribution to the bearings, rocker arm mechanisms and other functional parts.
1.3.5
Cooling System. Coolant is circulated through the engine by a centrifugal type
water pump. Heat is then removed from the coolant, which circulates in a closed
loop system, via the radiator. Control of the engine temperature is accomplished
by thermostats that regulate the flow of the coolant within the coolant system.
1.3.6
Electrical System. Engine starting is provided by an electric starting system. The
electric starting motor is energized by a storage battery. A battery-charging alternator, with a built-in voltage regulator, serves to keep the battery charged.
1.3.7
Engine speed is regulated by the electronic control module (ECM).
AIR COMPRESSOR DESCRIPTION
1.4.1
The TR/TMD-150/180/250 incorporates a rotary screw single stage GHH-RAND
(CD26S/CD42S) air compressor that is driven by a Detroit Diesel 4-cycle engine.
The power transmission from the engine to the compressor is through step-up
gears, via a resilient coupling.
1.4.2
The compressor casing houses a screw type, precision-machined, male and female
meshing rotor mounted on an angular contact single row ball bearings. The rotors
are bored and relieved for internal cooling. Sealing rings on the rotor shafts
CD295
5395
Chapter 1
Section 1
prevent the lubricating and cooling oil from entering the rotor housing, thus the
air delivery is completely oil-free. There is no surface contact between the rotors
and casing. The male rotor, which is driven by the engine, drives the female rotor
through a set of timing gears which maintain the slight clearance provided
between the male and female rotor lobes.
1.4.3
As the rotors rotate, the air in the interlobal spaces is forced towards the
compressor outlet end by the slide valve action of the meshing rotors. The lobe of
the male rotor moves along the groove of the female rotor, pushing the entrapped
air before it. As the air is compressed, the volume decreases. The compression
continues until the outlet end of the groove in the rotor comes into line with the
outlet port. The compressed air is then forced smoothly into the outlet port until
the lobe of the male rotor reaches the end of the groove. At this point, the next
groove has come into line with the outlet port, thus maintaining a continuous air
delivery free of pulsation.
1.4.4
The absence of metal to metal contact between the rotors, and between the rotors
and casing, eliminates practically all wear and friction loss.
1.4.5
The engine and compressor and their auxiliary equipment are completely
enclosed in a canopy which has two (2) doors, giving easy access to the engine
and compressor for normal maintenance.
1.4.6
The unit is equipped with a 24 volt, negative ground electrical system.
1.4.7
Oil System: Cooling and Lubrication. (See Figure 1.2, Oil Circulation Cooling
and Lubrication.)
CD295
4327
a.
Oil is used in the compressor element for cooling as well as for lubrication.
b.
The compressor oil pump (13) draws oil from the compressor oil sump. The
pump is driven by a gear on the compressor drive shaft and delivers approximately 11 GPM (50 liters per minute).
c.
Upon startup, the oil pump pushes oil to the thermostatic valve (1), which
then diverts oil to the oil manifold (2) where the oil then returns to the oil
sump.
d.
Once the unit has been running long enough for the oil to heat up to 120 °F
(49 °C), the thermostatic valve (1) opens and allows oil to flow to the heat
exchanger (14), where it then returns to the oil manifold (2) before being
dumped back into the sump to be recirculated.
e.
Whether the unit is cold or sufficiently warmed up, oil always flows
through the oil manifold (2). This is where all oil temperatures and
pressures are monitored.
f.
Once oil returns to the sump, it is pressure regulated and filtered within the
sump housing before flowing to the various cooling ports on the compressor
rotor casing and gearbox casing.
1-1-3
Orig
Chapter 1
Section 1
1.
2.
3.
4.
5.
6.
7.
8.
Thermostatic Valve
Oil Temperature Sensors,
Compressor Manifold
Straight Adapter
Straight Adapter
Straight Adapter
Close Nipple
Straight Adapter
Straight Adapter
Figure 1.2
1.5
11.
12.
13.
14.
Schematic, Lube Oil GHH Compressors
Dual Pressure Regulation of Air Supply. This system provides a dual pressure air
delivery system for both the JET START and AIR PACKS mode of operation.
(See Figure 1.3)
a.
The JET START position delivers air at 42 psig (250 kPa), nominal.
b.
The AIR CONDITION position delivers air at 24 psig (165 kPa), nominal.
OPERATION
1.6.1
Theory of Operation. The primary components and their functions for the TR/
TMD-150/180/250 are as follows:
a.
1-1-4
Orig
10.
Compressor Pump to Thermal
Valve Hose Assembly
Thermal Valve to Oil Cooler Hose
Assembly
Oil Cooler to Oil Manifold Hose
Assembly
Oil Manifold to Compressor Hose
Assembly
Compressor Oil Pump
Heat Exchanger
AIR REGULATION SYSTEM DESCRIPTION
1.5.1
1.6
9.
Mode selector Switch. The mode selector switch has three operating
positions: UNLOAD, JET START, and AIR PACKS. The switch is an
operator control point that generates signals to a series of solenoid valves.
CD295
4327
Figure 1.3
Dual Pressure Air Regulation System
Chapter 1
Section 1
CD295
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1-1-5
Orig
Chapter 1
Section 1
1.6.2
b.
Solenoid Valves. The solenoid valves receive an electrical signal via the
mode selector switch. Depending on which mode the selector switch is
placed, the appropriate solenoid valves open (energize) or close (deenergize) to allow a control air signal to the unloader valve.
c.
Pressure Regulators. The pressure regulators receive a sense air signal from
the discharge manifold. Depending on which mode the selector switch is
placed, the appropriate pressure regulator regulates a pilot air signal to the
unloader valve. The unloader valve is then able to regulate the appropriate
system pressure. The regulators regulate sense air in all modes at all times.
d.
Unloader Valve. The unloader valve receives a control (pilot) air signal
from the pressure regulators. The control air signal closes the unloader
valve allowing it to regulate to the appropriate system pressure. When the
mode selector switch is placed in the UNLOAD mode, there is no control
air signal to the unloader valve, thus allowing the unloader valve to vent
discharge air to atmosphere.
e.
Unload Air Silencer. The silencer is connected via piping and connectors to
the exhaust (atmospheric) side of the unloader valve. The silencer is packed
with sound attenuating material and an oversized outlet to attenuate or
dampen the sound pressure level of the compressor discharge air to
atmosphere.
f.
Safety Pressure Relief Valve. The safety pressure relief valve is mounted
directly on the compressor discharge pipe. It is set to open, thus venting to
atmosphere, at 52 psig (358kPa) ±5 psig. The safety pressure relief valve is
designed to relieve the full capacity of the compressed air discharge should
the unloader valve fail in the closed position.
Modes of Operation. (See Figure 1.3.)
There are three modes of operation with five control air circuit variations. The
three modes of operation are (1) UNLOAD, (2) AIR PACKS, and (3) JET START.
The five control air circuit variations are:
1.
UNLOADE mode with discharge air to atmosphere.
a.
2.
1-1-6
Orig
The common, AIR PACKS, and JET START solenoid valves are deenergized (closed) with no control (pilot) air signal to the unloader
valve and engine speed at idle (1100 rpm).
AIR PACKS mode with no demand for discharge air.
a.
The AIR PACKS solenoid valve is energized (open) allowing the AIR
PACKS pressure regulator control (pilot) air signal to the unloader
valve, thus maintaining AIR PACKS system pressure and engine
speed at idle (1100 rpm).
b.
The common solenoid valve is de-energized (closed) and no
additional control (pilot) air signal passes to the unloader valve.
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Figure 1.3
Dual Pressure Air Regulation System
Chapter 1
Section 1
CD295
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1-1-7
Orig
Chapter 1
Section 1
3.
4.
5.
1.7
The AIR PACKS solenoid valve is energized (open) allowing the AIR
PACKS pressure regulator control (pilot) air signal to the unloader
valve.
b.
The common solenoid valve is energized (open) and an additional
control (pilot) air signal passes to the unloader valve, thus
maintaining AIR PACKS system pressure and engine speed at 2100
rpm or less, depending on the amount of demand for discharge air
from the aircraft.
JET START mode with no demand for discharge air.
a.
The JET START solenoid valve is energized (open) allowing the JET
START pressure regulator control (pilot) air signal to the unloader
valve, thus maintaining JET START system pressure and engine speed
at idle (1100 rpm).
b.
The common solenoid valve is de-energized (closed) and no
additional control (pilot) air signal passes to the unloader valve.
JET START mode with demand for discharge air.
a.
The JET START solenoid valve is energized (open) allowing the JET
START pressure regulator control (pilot) air signal to the unloader
valve.
b.
The common solenoid valve is energized (open) and an additional
control (pilot) air signal passes to the unloader valve, thus
maintaining JET START system pressure and engine speed at 2100
rpm or less, depending on the amount of demand for discharge air
from the aircraft.
(Refer to Drawings SS000009, SS000010, and SS000011.) The engine electronic
control module (ECM) is the heart of the system. This is a non-repairable item
that should be replaced as a unit. A schematic is not provided for the ECM; all
required information is provided on the drawings. Should the ECM become
defective, a replacement assembly may be ordered from TUG Technologies
Corporation.
STARTING CIRCUIT
1.8.1
1-1-8
Rev 6
a.
ELECTRICAL PRINCIPLES OF OPERATION
1.7.1
1.8
AIR PACKS mode with demand for discharge air.
The mode selector switch (S10) is in the UNLOAD position. The operator presses
the engine crank switch (S1) and the auxiliary starting coil (K2 and K3) is
energized from the unit's series-connected batteries (BT1A, BT1B, BT2A, and
BT2B). When the auxiliary starting coil is energized, its normally open contacts
close, energizing the engine starting solenoid (L1). As a result, the L1 contacts
close and voltage from the batteries is applied to the engine starting motor (B1)
CD295
Chapter 1
Section 1
and the engine cranks for starting. The attempt start circuit is provided necessary
voltage when the K2 and K3 contacts are closed. The attempt start circuit causes
the ECM to energize the governor to the full fuel position.
1.8.2
1.9
When the engine starts, the operator releases the engine start switch (S1), causing
the auxiliary start coil (K2 and K3) to de-energize, opening the auxiliary starting
coil contact, and the L1 de-energizes. In turn, the L1 contacts open and the
engine starting motor (B1) de-energizes. When the engine reaches 500 rpm, the
engine running indication and crank disconnect relay (K1) energizes, applying 24
volts to the assembly. As a result, a normally closed contact which is in the crank
circuit for K2 and K3 will open to prevent accidental starter attempt while the
engine is running.
AUTOMATIC SHUTDOWN PROTECTIVE CIRCUIT
1.9.1
1.9.2
1.9.3
Engine High Coolant Temperature. Should the engine coolant temperature exceed
approximately 205 °F (96 °C), the engine high coolant temperature sensor (SE4)
will send a signal to the ECM and the following will occur:
a.
The ECM assembly will send a signal, illuminating the ENGINE
TROUBLE lamp (DS10), which will remain illuminated until it is manually
reset by actuation of the TROUBLE RESET switch (S15).
b.
The ENGINE TROUBLE lamp (DS10) will provide a visual warning of an
abnormal condition.
c.
The unit will shut down, except when the unit is operating in the JET
START mode.
Engine Low Oil Pressure Circuit. In the event the engine oil pressure drops below
10 psi (69 kPa), the engine oil pressure sensor (SE3) will send a signal to the
ECM. The following will occur:
a.
The ECM will send a signal, illuminating the ENGINE TROUBLE lamp
(DS10), which will remain illuminated until it is manually reset by
actuation of the TROUBLE RESET switch (S15).
b.
The ENGINE TROUBLE lamp (DS10) will provide a visual warning of an
abnormal condition.
c.
The unit will shut down, except when the unit is operating in the JET
START mode.
Compressor High Oil Temperature Circuit. If the compressor oil temperature
exceeds 185 °F (85 °C), the compressor high oil temperature switch (S3) will
send a signal to the ECM assembly, with the following results:
a.
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There will be a signal to the ECM assembly, illuminating the high
compressor oil temperature lamp (DS3) and that will remain illuminated
until it is manually reset by actuation of the TROUBLE RESET switch
(S15).
1-1-9
Orig
Chapter 1
Section 1
1.9.4
1.9.5
b.
The ENGINE TROUBLE lamp (DS10) will provide a visual indication of
an abnormal condition.
c.
The unit will shut down, except when the unit is operating in the JET
START mode.
Compressor High Discharge Air Temperature Circuit. This circuit detects a HIGH
AIR TEMPERATURE condition in the discharge manifold. This is sensed by
temperature switch (S4), which switches at temperatures over 460 °F (238 °C). In
operation, the S4 senses the air temperature at stage one and if switch (S4)
detects a high temperature condition, a signal will be applied to the ECM
assembly, with the following results:
a.
The ECM assembly will send a signal, illuminating the COMPRESSOR
HIGH DISCHARGE AIR TEMPERATURE lamp (DS4), that will remain
illuminated until the TROUBLE RESET switch (S15) is manually activated.
b.
The COMPRESSOR HIGH DISCHARGE AIR TEMPERATURE lamp
(DS4) will provide a visual warning of an abnormal condition.
c.
The unit will shut down, except when the unit is operating in the JET
START mode.
Compressor Low Oil Pressure Circuit. In the event the compressor oil pressure
drops below 10 psig (69 kPa), the COMPRESSOR LOW OIL PRESSURE switch
(S5) will send a signal to the ECM assembly, which starts a 10-second delay
(TD2). If, at the end of this delay period, the S5 is still closed, the following will
occur:
a.
The ECM assembly will send a signal, illuminating the COMPRESSOR
LOW OIL PRESSURE lamp (DS5), which will remain illuminated until the
TROUBLE RESET switch (S15) is manually activated.
b.
The COMPRESSOR LOW OIL PRESSURE lamp (DS5), will provide a
visual warning of an abnormal condition.
c.
The unit will shut down, except when the unit is operating in the JET
START mode.
1.10 NORMAL SHUTDOWN CIRCUIT
1.10.1 When the operator presses the ENGINE STOP switch (S2), power is removed
from the engine run relay, and time delay relay (TD1) times the cooldown period.
1-1-10
Rev 2
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Chapter 1
Section 1
1.11 EMERGENCY SHUTDOWN CIRCUIT
1.11.1 When the EMERGENCY STOP switch (S9) is closed, a signal is sent to the ECM.
To activate the Emergency Stop Switch, depress the red mushroom Emergency
Stop pushbutton. The pushbutton operator will latch in the depressed position. To
reset the switch, rotate the pushbutton operator in the direction of the arrow, and
pull the operator out to the unlatched position.
Do not use the emergency stop to stop the engine except in an
emergency.
1.12 MISCELLANEOUS CIRCUITS
1.12.1 Panel Lights Circuit. When the PANEL LAMPS switch (S12) is closed, the
battery voltage illuminates the panel lamps (DS12A, DS12B, and DS12C).
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Chapter 1
Section 1
This Page Intentionally Left Blank
1-1-12
Orig
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Chapter 1
Section 2
Chapter 1, Section 2
Operation
2.1
PRE-OPERATIONAL CHECKS
Before using the equipment, the operator should carefully read the
instructions in this section and become familiar with the unit’s
controls and indicators, described in Table 1.2 of this section.
2.1.1
In order to ensure safe, reliable operation, perform the following checks prior to
operating the unit:
a.
Stop the unit at the proper location and set parking brake. (Push handle
down as far as it will go.) Block tires with chocks.
b.
Walk around and inspect the unit for damage or missing equipment. Ensure
that all required procedures listed in Chapter 2 have been performed.
Remember to check for the following:
1.
Damaged or underinflated tires. Look for cuts, cracks in sidewalls, or
foreign objects in treads.
2.
Loose wheel nuts.
3.
Proper operation of hitches.
c.
Look underneath the unit for leaks of coolant or lubricating oil. If significant leaks in any of these systems are found, repair as soon as possible.
d.
Check engine and compressor oil levels.
Do not loosen or remove radiator cap while coolant is hot. Hot
coolant under pressure can cause severe burns.
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e.
Check engine coolant level. Add coolant as necessary, but do not overfill.
f.
Inspect engine compartment for loose hardware, loose wires, and leaking
lines or fittings.
g.
When all mechanical checks are completed, check the operation of all
lights.
1-2-1
Orig
Chapter 1
Section 2
h.
Note:
2.2
Check fuel level by lifting upon fuel level switch. Fill tank if required.
Fuel contamination owing to moisture condensing on the inner surfaces of
the fuel tank can be minimized or eliminated by keeping the fuel tank as full
as possible. The fuel tank should always be topped off at the end of the day’s
operation, as part of the post-operation maintenance routine.
STARTING PROCEDURES
This unit is to be operated only by authorized trained personnel
wearing appropriate ear protection. Before operating unit, read
unit manual. This unit is equipped with an emergency stop switch,
which is to be used only for emergency conditions.
2.2.1
Set parking brake and block tires with chocks.
2.2.2
Check fuel level by lifting up on fuel level check switch. Fill tank if required.
2.2.3
If ambient temperature is below 10 o F (-12 o C) and unit is equipped with optional
fuel heater, place fuel heater switch in on position ten minutes prior to starting
engine.
2.2.4
Disconnect optional oil/coolant/battery heater electrical power (if applicable).
2.2.5
Check engine and compressor oil levels.
2.2.6
Place compressor mode selector switch in unload position.
2.2.7
Close air delivery/cutoff valve(s) and air bleeddown ball valve(s).
2.2.8
Connect air hose(s) to aircraft.
Ensure personnel and loose items are clear of the unit before
starting engine.
2.2.9
1-2-2
Orig
Place the engine run-stop switch in the run position. The check engine light and
engine trouble light will come on providing automatic lamp check. Allow several
seconds for these lights to go out.
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Chapter 1
Section 2
2.2.10 Verify that all fault lamp bulbs on the control panel are functioning by lifting up
momentarily on the lamp test switch.
To avoid overheating the starter motor, do not operate the starting
motor for more than 30 seconds without allowing a minimum
cooling period of at least 2 minutes.
2.2.11 To start engine, lift up on engine start switch; release switch immediately when
engine starts. Do not crank engine for more than 15 seconds at a time, with a 30
second rest between cranks.
2.2.12 Ensure all engine/compressor trouble lights are dark. If any are illuminated, place
engine run-stop switch in stop position and correct the problem before
proceeding. If only the check engine light comes on, operation may be continued:
see engine diagnostics section.
2.2.13 Check compressor and engine gauges for normal operating conditions. Run unit
in unload mode for approximately 5 minutes to allow engine to warm up. Engine
idle speed is 1100 rpm.
2.2.14 Ensure that air hose(s) are still properly connected to aircraft.
Do not operate mode selector switch unless the delivery hose is
uncoiled and stretched out or connected to the aircraft. The
delivery hose should be kept in good condition and thoroughly
inspected. Moreover, personnel should use caution when near hose
as contact with high-pressure, high-temperature air is dangerous.
The engine and compressor safeties are bypassed in JET START
mode. Therefore, the unit is to be operated in jet start mode only
when the pilot is ready to start the aircraft engines. If an engine or
compressor trouble light comes on while unit is being operated in
jet start mode and an aircraft is being started, do not shut unit
down as aircraft engine could be damaged. If an aircraft engine is
not being started, advise aircraft pilot that start is to be aborted;
then place mode selector switch in unload.
Unit should shut down automatically within 30 seconds. (Refer to
engine diagnostics section for diagnosing engine problem). If unit
does not shut down after 30 seconds, shut it down with the
emergency stop switch.
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1-2-3
Orig
Chapter 1
Section 2
2.2.15 With air delivery/cutoff valve(s) and air bleeddown ball valve(s) still closed,
place compressor mode selector switch in jet start or air packs position as
required. The engine will momentarily speed up, then return to idle speed.
Never open air delivery/cutoff valve(s) without the air hose(s) being
properly connected to an aircraft or test fixture.
2.2.16 Open air delivery/cutoff valve(s) of selected hose(s).
Note:
2.3
This unit has an automatic throttle control system. Engine will speed up as
required in response to aircraft air demand, and will return to idle when there
is no/low demand. Maximum engine speed is 2100 rpm in AIR PACKS and
JET START modes.
SHUTDOWN PROCEDURES
2.3.1
Place compressor mode selector switch in unload position.
2.3.2
Place the engine run-stop switch in stop position. The engine will continue to run
for approximately 5 minutes, allowing the compressor and engine turbo to cool
down before the engine is automatically shut down.
For immediate shutdown. The emergency stop switch may be used
only for emergency conditions.
2.3.3
If fuel heater switch was placed on, return it to the off position. Failure to do so
will discharge battery.
2.3.4
Close air delivery/cutoff valve(s).
2.3.5
Open bleeddown ball valve(s) to relieve any pressure remaining in the hose(s).
Do not unplug air hose(s) with mode selector switch in AIR PACKS
or JET START position, as hose(s) will be under pressure.
Hose temperatures may be near 500 o F (260 o C) after the unit has
been operated. Therefore, wait until the air hose coupling has
cooled or use appropriate gloves to protect hands.
1-2-4
Rev 2
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Chapter 1
Section 2
2.3.6
Unplug air hose(s) from aircraft and store them.
2.3.7
Remove wheel chocks and release parking brake before moving unit.
2.3.8
After moving unit, set parking brake and block tires with chocks.
2.3.9
Reconnect optional oil/coolant/battery heater electrical power (if applicable).
2.3.10 Close the manual bleeddown valve.
2.3.11 Perform any necessary maintenance procedures as listed in Chapter 2, Section 1.
2.4
ENGINE PROTECTIVE SHUTDOWNS
2.4.1
In the AIR PACKS mode, the unit will shut down automatically from high engine
coolant temperature, low engine oil pressure, high compressor air temperature,
high compressor oil temperature, and low compressor oil pressure, as specified in
Chapter 1, Section 1.
Ta ble 1 . 1 NO R M A L O P E R AT I N G C O N D I T I O N S
Engine Oil Pressure (2110 rpm)
4 0 – 6 0 p s i ( 2 7 6 – 4 1 4 k Pa ) ( a p p r ox . )
Engine Speed
Idle:
1100 r pm
O p e ra t i o n :
2110 rpm
C o m p r e s s o r A i r Te m p e r a t u r e
Idle (1100 rpm):
( A t a m b i e n t t e m p e ra t u r e 8 5 ° F ( 2 9 ° C ) )
250 °F (121 °C)
D u r i n g O p e ra t i o n
J E T S TA RT M o d e :
410 °F (210 °C)
N OT E : A I R C O N D I T I O N m o d e m ay b e s li g h t ly l owe r.
C o m p r e s s o r O i l Te m p e ra t u r e
120–176 °F (49–80 °C)
Compressor Oil Pressure
L OA D E D :
2 5 p s i ( 1 7 2 k Pa )
U N L OAD E D :
1 5 p s i ( 1 0 3 k Pa )
Compressor Air Pressure
4 2 p s i g ( 2 5 0 k Pa ) J E T S TA RT m o d e
2 4 p s i g ( 1 6 5 k Pa ) A I R PAC K S m o d e
Fuel Pressure
Idle (Unloaded):
1 5 – 2 0 p s i ( 1 0 3 – 1 3 8 k Pa )
AIR CONDITION or
J E T S TA RT M o d e :
7 0 – 8 0 p s i ( 4 8 3 – 5 5 2 k Pa )
C o o l a n t Te m p e r a t u re
170–200 °F (77–93 °C)
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Chapter 1
Section 2
2.5
AIR START UNIT CONTROLS AND INDICATORS
2.5.1
The air start unit employs a complete complement of indicators and controls that
monitor and govern all facets of its operation. The following table lists these
controls and indicators and explains the specific function of each. Please refer to
Figure 1.4 and Table 1.2.
Figure 1.4
1-2-6
Rev 2
Control Panel (Sheet 1 of 4)
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Chapter 1
Section 2
Ta ble 1 . 2 CO N T RO L S AN D I ND I C ATOR S (F I G U RE 1 . 4 )
N AM E O F C ON T RO L
ITEM F UN CT I ON
O R I N D I C ATO R
NO.
PANEL Lamp
(DS12A, DS12B, DS12C)
1
The Panel lamps (DS12A, DS12B, DS12C) illuminate the
control when the PANEL LIGHT switch (S12) is placed in the
ON position.
COMPRESSOR AIR
TEMPERATURE Gauge
2
The COMPRESSOR AIR TEMPERATURE gauge indicates
the discharge air temperature of the air in the discharge
manifold. Normal indication of this instrument at an ambient
temperature of 85 °F (29 °C) is approximately 410 °F
(210 °C) when operating in the JET START mode. Normal
readings are slightly lower for the AIR PACKS mode of
operation. Maximum safe discharge air temperature is
approximately 502 °F (261 °C)
COMPRESSOR AIR PRESSURE
Gauge
3
The COMPRESSOR AIR PRESSURE gauge indicates the
discharge air pressure. Normal pressure indications is
approximately 24 psiG (165 kPa) when operating in the AIR
PACKS mode or 42 psiG (250 kPa) in JET START mode.
COMPRESSOR OIL
TEMPERATURE Gauge
(GA6)
4
The COMPRESSOR OIL TEMPERATURE gauge (GA6) is
gauge displays the current compressor oil temperature,
normally 120–176 °F (49–80 °C).
COMPRESSOR OIL PRESSURE
Gauge (GA5)
5
The COMPRESSOR OIL PRESSURE gauge (GA5) monitors
the compressor lube oil pressure in psi. When operating in the
AIR PACKS or JET START mode, the gauge should read
between 25-30 psi (172-207 kPa). When the compressor is
unloaded, this gauge should read between 20-25 psi (103172 kPa).
FUEL PRESSURE Gauge
(GA2)
6
The FUEL PRESSURE gauge (GA2) indicates the relative
fuel pressure of the engine. Normal fuel pressures are
approximately 15–20 psi (103–138 kPa) when the compressor
is unloaded (engine idling) and 70–80 psi (483–552 kPa)
when operating in the AIR PACKS or JET START modes
(engine running at the rated rpm).
ENGINE WATER TEMPERATURE
Gauge (GA4)
7
The ENGINE WATER TEMPERATURE gauge (GA4)
monitors the engine coolant temperature. Normal indication
(following engine warm-up) is 170–200 °F (77–93 °C).
ENGINE OIL PRESSURE Gauge
(GA3)
8
The ENGINE OIL PRESSURE gauge monitors the engine
lube oil pressure in psi. Normal indication at rated rpm is 40–
60 psi (276–414 kPa).
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1-2-7
Rev 2
Chapter 1
Section 2
Figure 1.4
1-2-8
Rev 2
Control Panel (Sheet 2 of 4)
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Chapter 1
Section 2
Ta ble 1 . 2 CO N T RO L S AN D I ND I C ATOR S (F I G U RE 1 . 4 ) (C o n t . )
N AM E O F C ON T RO L
O R I N D I C ATO R
ITEM
NO.
F UN CT I ON
FUEL LEVEL CHECK Switch (S16)
9
Activation of the FUEL LEVEL CHECK switch (S16) will
test the fuel gauge, ensuring there is an accurate reading.
TACHOMETER
10
The tachometer (GA7) is a mechanically operated instrument
that indicates engine speed in revolutions per minute.
FUEL LEVEL Gauge
(GA1)
11
The FUEL LEVEL gauge (GA1) indicates level of fuel in the
unit tank.
VOLTMETER Battery Charge Output
(M1)
12
The battery Voltmeter (M1) monitors the battery charging
current from the battery charging alternator or discharge
current from the battery.
UNIT IN COOLDOWN MODE Lamp
(DS2) (AMBER)
13
The UNIT COOLDOWN MODE lamp (DS2) will illuminate
when the RUN/STOP switch (S2) is placed in the STOP
position to shut down the unit. (The unit will run at 1100 rpm
(idle speed) for five minutes.)
COMPRESSOR HIGH OIL
TEMPERATURE Lamp (DS3)
(RED)
14
Illumination of the COMPRESSOR HIGH OIL
TEMPERATURE lamp (DS3) indicates that the engine
coolant temperature has risen above 176 °F (80 °C).
COMPRESSOR LOW OIL
PRESSURE Lamp (DS5)
(RED)
15
While the engine is running, the COMPRESSOR LOW OIL
PRESSURE lamp (DS5) will illuminate if the compressor oil
pressure drops below 10 psi (69 kPa).
COMPRESSOR HIGH DISCHARGE
AIR TEMPERATURE Lamp (DS4)
(RED)
16
Illumination of the COMPRESSOR HIGH DISCHARGE AIR
TEMPERATURE lamp (DS4) indicates that compressor air
discharge temperature has risen above 502 °F (261 °C).
LAMP TEST Switch (S13)
17
The LAMP TEST Switch (S13) is used to test the warning
lights located on the instrument panel except for the CHECK
ENGINE and BATTERY CHARGE Lamps. When actuated,
the warning lamps will illuminate.
TROUBLE RESET Switch (S15)
18
The TROUBLE RESET switch (S15) is a normally closed
toggle switch that is used to restore the safety circuits
employed in the power unit, following actuation caused by an
abnormal operating condition. Activation of the TROUBLE
RESET switch will extinguish all fault lamps, resetting the
safety circuits. (HOLD FOR 3 SECONDS.)
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Chapter 1
Section 2
Figure 1.4
1-2-10
Rev 2
Control Panel (Sheet 3 of 4)
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Chapter 1
Section 2
Ta ble 1 . 2 CO N T RO L S AN D I ND I C ATOR S (F I G U RE 1 . 4 ) (C o n t . )
N AM E O F C ON T RO L
O R I N D I C ATO R
ITEM
NO.
F UN CT I ON
E X C E PT I N AN E M ER G EN C Y, D O N OT U SE T H E
E M ER G E N C Y S TO P S W I T C H TO S TO P T H E
ENGINE.
EMERGENCY STOP Switch (S9)
19
The EMERGENCY STOP switch (S9), when in the closed
position, energizes. Thus, the EMERGENCY STOP switch
provides an alternative method of stopping the engine in an
emergency, or in the event the primary shutdown mechanism
fails.
PANEL LAMPS Switch (S12)
20
The PANEL LAMPS switch (S12) is a maintained contact
toggle switch that is used to illuminate and extinguish the
control panel lamp.
BATTERY CHARGER NOT
OPERATING Lamp (DS1) (RED)
21
Illumination of the BATTERY CHARGER NOT OPERATING
lamp (DS1) indicates the alternator charging system is not
providing voltage to the battery.
CHECK ENGINE FOR MINOR
PROBLEM Lamp (DS11) (AMBER)
22
Illumination of the engine CHECK ENGINE FOR MINOR
PROBLEM lamp (DS11) indicates that an engine malfunction
exists (such as low fuel pressure). The unit will continue to run.
ENGINE TROUBLE Lamp (DS10)
(RED)
23
The ENGINE TROUBLE lamp (DS10) will illuminate when
there is a signal from the ECM that there is a major problem
with on e of the unit systems. Unit will shut down.
EMERGENCY STOP Lamp (DS9)
(RED)
24
The EMERGENCY STOP lamp (DS9) will illuminate when the
Emergency Stop Switch (S9) has been activated.
ENGINE DIAGNOSTIC Switch (S6)
25
When ENGINE DIAGNOSTIC switch (S6) is activated, it will
test the flash codes in the DDEC control box.
LOSS OF VOLTAGE TO SAFETY
CIRCUITS Lamp (DS6) (RED)
26
The LOSS OF VOLTAGE TO SAFETY CIRCUITS lamp (DS6)
will illuminate when there is a loss of voltage to the safety
circuits.
LOW FUEL LEVEL Lamp (DS8)
(RED)
OPTIONAL
27
Illumination of LOW FUEL LEVEL lamp (DS8) indicates that
the fuel level has dropped to within 1/2 inch (12.7 mm) from the
bottom of the fuel tank (approximately 1 hour of run time). The
Low Fuel Level Beacon (DS7) blue lamp on outside of unit will
also be activated.
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Chapter 1
Section 2
Figure 1.4
1-2-12
Rev 2
Control Panel (Sheet 4 of 4)
CD295
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Chapter 1
Section 2
Ta ble 1 . 2 CO N T RO L S AN D I ND I C ATOR S (F I G U RE 1 . 4 ) (C o n t . )
N AM E O F C ON T RO L
O R I N D I C ATO R
MODE SELECTOR Switch (S10)
ITEM
NO.
28
F UN CT I ON
The MODE SELECTOR switch has three positions as follows:
UNLOAD
In the UNLOAD position, the engine is at idle speed, and the
discharge pressure is reduced to near atmospheric. The mode
selector switch must be in the UNLOAD position when starting
or stopping the unit, and when air is not required.
JET START
Prior to placing the mode selector switch in the JET START
position, the air delivery hose(s) must be uncoiled and stretched
out or connected to the aircraft with discharge valves closed. In
this mode of operation, the engine will maintain maximum safe
speed and the unit will deliver air at full capacity. Abnormal
operation conditions (listed in Section 2) will cause the
compressor and engine fault lamp to flash.
AIR PACKS
Prior to placing the mode selector switch in the AIR PACKS
position, the air delivery hose(s) must be uncoiled and stretched
or connected to the aircraft with discharge valves closed. In this
position, the engine will maintain maximum safe speed and the
unit will deliver air at full capacity. In the AIR PACKS mode,
all safety shutdowns are in effect and will shut down the unit
upon their individual actuation. Compressor and engine fault
lamp on the control panel will flash.
ENGINE CRANK Switch (S1)
The ENGINE CRANK switch (S1), when actuated, initiates
starting of the engine by causing the engine starter solenoid to
energize.
ENGINE STOP/RUN Switch (S2)
The ENGINE STOP/RUN switch (S2) is used for normal
stopping of the engine. When actuated, this switch sends a
signal to the DDEC control box for the unit to go into the
cooldown mode for 5 minutes at 1100 rpm and then shuts the
unit down.
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Chapter 1
Section 3
Chapter 1, Section 3
Specifications
3.1
INTRODUCTION
3.1.1
3.2
The following specification tables provide important data as to the characteristics
of the Model TR/TMD-150/180/250 Air Start Unit and its related components.
SPECIFICATION TABLES
3.2.1
General specifications and fuel capacities for the TR/TMD-150/180/250 Air Start
Unit and related components are listed in Tables 1.3 through 1.6.
3.2.2
Engine Oil Grades: For the SAE viscosity grades of engine oil to use at various
temperatures, refer to the Detroit Diesel Operator’s Manual located in Chapter 6,
Tab B.
Ta ble 1 . 3
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-150 Air Start Unit
A. Engine
•
M a n u f ac t u r e r
D e t r o i t D i e se l
•
Ty p e
D i r e c t i n j e c t i o n 4 c y c l e t u r b o c h a rg e d
•
Model
Series 60 12.7 liter DDEC IV
•
Rating
4 2 5 br a k e h o r s e p o w e r ( 3 1 7 kW )
•
Number of cylinders
Six (6)
•
Speed (idle)
11 0 0 r p m
•
S p e e d ( m a x . w he n l o a d e d)
2100 rpm
B. Compressor
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•
M a n u f ac t u r e r
GHH-RAND
•
Ty p e
R o t a r y d r y s c r e w oi l f r e e a i r
•
Model
CD26S (single element)
•
Output at 68 °F (20 °C), 0% RH,
s ea l e v el
1 5 0 lb / m i n ( 6 8 k g / m i n )
•
D i s ch a rg e p r e ssu r e ( m a x .)
(No. 2 diesel and Jet A fuels)
42 psi (289 (kPa)
•
D i s c h a rg e a i r t e m p e r a t u r e
3 9 0 °F (200 °C) nominal
1-3-1
Orig
Chapter 1
Section 3
Ta ble 1 . 3
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-150 Air Start Unit (Cont.)
C . E n g i n e a n d C o m p r e s s o r P ro t e c t i o n S y s t e m
O p e r a t i n g c o n d i t i o n s b e l o w a re f a c t o r y s e t f o r o p e r a t o r w a r n i n g a n d / o r a u t o m a t i c
s h u td o w n i n “U N L O A D ” an d “ A I R PA C K ” m o d e s o n l y. O n l y s h u td o w n i n “J E T
S TA RT ” m o d e i s a n o p e r a t o r E m e rg e n c y St o p .
•
E n g in e h i g h c o o l a n t t e m p e r a t u r e
217 °F (103 °C)
•
E n g in e l o w o il p r e s s u r e
1 0 ps i ( 6 9 k P a )
•
Compressor high air temperature
502 °F (261 °C)
•
Compressor high lube oil
temperature
176 °F (80 °C)
•
Compressor low lube oil pressure
1 0 ps i ( 6 9 k P a )
D. A i rc r a f t P ro te c t i o n S y s t e m
•
D i s c h a rg e a i r r e g u la t i n g v a l v e
4 2 ps i ( 2 8 9 kP a )
•
D i s c h a rg e a i r s a f e t y v a lv e
5 2 ps i ( 3 5 9 kP a )
E . D i m e n s i o n s a n d We i g h t s
TMD-150
(trailer unit)
TRD-150
( m o d u l e o n ly )
Length
14'-8" (4.5 m)
10'-9" (3.3 m)
Width
6'-10" (2.1 m)
6'-10" (2.1 m)
Height
7'-3" (2.2 m)
6'-10" (2.1 m)
11,050 lb (5,023 kg)
10,350 lb (4,705 kg)
Weight (dry)
TRD-150 + truck GVW
Specifications are subject to change without notice at the sole discretion of TUG
Technologies Corporation (2/1/00).
Ta ble 1 . 4
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-180 Air Start Unit
A. Engine
1-3-2
Rev 6
•
M a nu f ac t u r e r
D e t r o i t D i e se l
•
Ty p e
D i r e c t i n j e c t i o n 4 c y c l e t u r b o c ha rg e d
•
Model
Series 60 12.7 liter DDEC IV
•
R a t i ng
500 brake horsepower (373 kW)
•
Number of cylinders
Six (6)
•
Speed (idle)
11 0 0 r p m
•
Speed (max. when loaded)
2100 rpm
CD295
Chapter 1
Section 3
Ta ble 1 . 4
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-180 Air Start Unit (Cont.)
B. Compressor
•
M a n u f ac t u r e r
GHH-RAND
•
Ty p e
R o t a r y d r y s c r e w oi l f r e e a i r
•
Model
CD26S (single element)
•
Output at 68 °F (20 °C), 0% RH,
s ea l e v el
1 8 0 lb / m i n ( 8 2 k g / m i n )
•
D i s ch a rg e p r e ssu r e ( m a x .)
(No. 2 diesel and Jet A fuels)
42 psi (289 (kPa)
•
D i s c h a rg e a i r t e m p e r a t u r e
3 9 0 °F (200 °C) nominal
C . E n g i n e a n d C o m p r e s s o r P ro t e c t i o n S y s t e m
O p e r a t i n g c o n d i t i o n s b e l o w a re f a c t o r y s e t f o r o p e r a t o r w a r n i n g a n d / o r a u t o m a t i c
s h u t d ow n i n “ UN L O A D ” an d “ A I R PA C K ” m o d e s o n l y. O n l y s h u t do w n i n “ J E T
S TA RT ” m o d e i s a n o p e r a t o r E m e rg e n c y St o p .
•
E n g i ne h i g h c o o l a n t t e m p e r a t u r e
2 1 7 ° F ( 10 3 ° C )
•
E n g i ne l o w o i l p r e s s u r e
10 psi (69 kPa)
•
Compressor high air temperature
5 0 2 ° F ( 26 1 ° C )
•
Compressor high lube oil
temperature
1 7 6 ° F ( 80 ° C ) ‘
•
Compressor low lube oil pressure
10 psi (69 kPa)
D. A i rc r a f t P ro te c t i o n S y s t e m
•
D i s c h a rg e a i r r e g u l a t i n g v a l v e
42 psi (289 kPa)
•
D i s c h a rg e a i r s a f e t y v a l v e
52 psi (359 kPa)
E . D i m e n s i o n s a n d We i g h t s
TMD-180
(trailer unit)
TRD-180
( m o d u l e o n ly )
Length
1 4 '- 8 " ( 4 . 5 m )
1 0 '- 9 " ( 3 . 3 m )
Wi d t h
6 '- 1 0 " ( 2 . 1 m )
6 '- 1 0 " ( 2 . 1 m )
Height
7 '- 3 " ( 2 . 2 m )
6 '- 1 0 " ( 2 . 1 m )
11 , 0 5 0 l b ( 5 , 0 2 3 k g )
10 , 3 5 0 l b ( 4 , 7 0 5 k g )
Wei g h t ( d r y )
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TRD-180 + truck GVW
1-3-3
Rev 2
Chapter 1
Section 3
Ta ble 1 . 5
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-250 Air Start Unit
A. Engine
•
M a nu f ac t u r e r
D e t r o i t D i e se l
•
Ty p e
D i r e c t i n j e c t i o n 4 c y c l e t u r b o c ha rg e d
•
Model
Series 60 14 liter DDEC IV
•
R a t i ng
630 brake horsepower (470 kW)
•
Number of cylinders
Six (6)
•
Speed (idle)
11 0 0 r p m
•
Speed (max. when loaded)
2100 rpm
B. Compressor
•
M a nu f ac t u r e r
GHH-RAND
•
Ty p e
Rotary dry screw oil free air
•
Model
CD42S (single element)
•
Output at 68 °F (20 °C), 0% RH,
s ea l e v el
2 5 0 l b / m i n ( 11 3 k g / m i n )
•
D i s ch a rg e p r e ssu r e ( m a x. )
(No. 2 diesel and Jet A fuels)
4 2 ps i ( 2 8 9 ( k P a )
•
D i s c h a rg e a i r t e m p e r a t u r e
3 9 0 °F (200 °C) nominal
C . E n g i n e a n d C o m p r e s s o r P ro t e c t i o n S y s t e m
O p e r a t i n g c o n d i t i o n s b e l o w a re f a c t o r y s e t f o r o p e r a t o r w a r n i n g a n d / o r a u t o m a t i c
s h u td o w n i n “U N L O A D ” an d “ A I R PA C K ” m o d e s o n l y. O n l y s h u td o w n i n “J E T
S TA RT ” m o d e i s a n o p e r a t o r E m e rg e n c y St o p .
1-3-4
Rev 2
•
E n g in e h i g h c o o l a n t t e m p e r a t u r e
217 °F (103 °C)
•
E n g in e l o w o il p r e s s u r e
1 0 ps i ( 6 9 k P a )
•
Compressor high air temperature
502 °F (261 °C)
•
Compressor high lube oil
temperature
176 °F (80 °C)‘
•
Compressor low lube oil pressure
1 0 ps i ( 6 9 k P a )
CD295
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Chapter 1
Section 3
Ta ble 1 . 5
Sp e c i f i c a t i o n s S t a n d a rd D e t ro i t D i e s e l
TR/TMD-250 Air Start Unit (Cont.)
D. A i rc r a f t P ro te c t i o n S y s t e m
•
D i s c h a rg e a i r r e g u l a t i n g v a l v e
42 psi (289 kPa)
•
D i s c h a rg e a i r s a f e t y v a l v e
52 psi (359 kPa)
E . D i m e n s i o n s a n d We i g h t s
TMD-250
(trailer unit)
TRD-250
(module only)
Length
1 4 '- 8 " ( 4 . 5 m )
1 0 '- 9 " ( 3 . 3 m )
Wi d t h
6 '- 1 0 " ( 2 . 1 m )
6 '- 1 0 " ( 2 . 1 m )
Height
7 '- 3 " ( 2 . 2 m )
6 '- 1 0 " ( 2 . 1 m )
1 2 , 3 0 0 l b ( 5 , 59 0 k g )
11 , 6 0 0 l b ( 5 , 27 3 k g )
Wei g h t ( d r y )
Ta ble 1 . 6
TRD-250 + truck GVW
Fluid Capacities, TR/TMD-150/180/250
A. Engine Coolant
B . E n g i n e F u e l D ay Ta n k
TR/TMD-150/180
TR/TMD-250
17-20 USG (64-76 L)
17-20 USG (64-76 L)
~ 1 0 3 U S G a l l o n s ( 3 90 L i t e r s ) , u s a b l e
C. Engine Lube Oil
8.75 USG (33 L)
8.75 USG (33 L)
D. C o m p r e s s o r L u b e O i l
10 USG (37.85 L)
10 USG (37.85 L)
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Chapter 1
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Chapter 1
Section 4
Chapter 1, Section 4
Shipping
4.1
INTRODUCTION
4.1.1
4.2
TIE-DOWN POINTS
4.2.1
4.3
This section contains instructions for the preparation of shipping the TR/TMD150/180/250 Air Start Unit from one location to another. Normally, shipping the
unit does not involve storage time. If the unit is to be stored before or after
shipment, refer to Section 5 of this chapter for details on preparation. The unit is
normally shipped in a fully operational status. The unit can be towed to on-load
or off-load from the trailer bed of the transporting truck. Any systems that are not
operational should be appropriately tagged on the unit and indicated on the
shipping document that accompanies the unit. If the fully operational method of
shipment is not preferable, refer to paragraphs 4.4 through 4.8.
There are two tie-down tubes located on the frame just in front of the rear tires;
two more tie-down access holes are located on the front fifth wheel fender well
(trailer-mounted model, TMD-150/180/250).
LIFTING
To avoid injury to personnel or damage to equipment, always use
lifting equipment, supports, and chains with a rated capacity of at
least one and one-half (1-1/2) times that of the object being lifted or
supported.
4.3.1
4.4
The unit may be lifted by a hydraulic lift (forklift) with, minimum, seven-foot
forks. Place forks under the main frame just outboard of the fuel tank supports.
PREPARING THE ENGINE AND COMPRESSOR
4.4.1
Drain fuel tank; close and seal all openings.
4.4.2
Drain coolant from engine cooling system; close and seal all openings.
4.4.3
Seal end of exhaust with weatherproof tape, to prevent entry of foreign matter.
4.4.4
Seal the compressor air intake by enclosing the air cleaner assembly in plastic
sheeting and securing with duct tape to prevent entry of foreign matter.
4.4.5
Seal the end of the engine intake with duct tape to prevent damage or foreign
matter to enter.
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1-4-1
Orig
Chapter 1
Section 4
4.5
PREPARING THE UNIT
4.5.1
4.6
Batteries.
a.
Disconnect the battery cables and securely fasten inside the enclosure to
prevent them from coming in contact with battery terminals.
b.
Ensure battery hold-down devices are installed and tightened.
4.5.2
Control Panel. Protect the control panel with cardboard or other suitable material
to prevent damage from impact by loose debris.
4.5.3
Warning Beacons. Remove roof-mounted beacon(s), if supplied, before shipment.
Securely tape a protective covering over the beacon mounting plate(s). Securely
pack roof-mounted beacon(s) in a box(es), label box(es), and ship with unit.
MARKING
4.6.1
Before shipment, ensure that a warning tag of some type is securely fastened to
the ENGINE START switch on the control panel. This tag should warn as to the
following:
Do not start engine! Coolant has been drained. Fuel has been
drained.
4.7
4.8
1-4-2
Orig
RECEIVING EQUIPMENT
4.7.1
Inventory. Inventory items received against shipper’s Bill of Lading. Note any
missing items on Bill of Lading.
4.7.2
Inspection. Inspect equipment for damage. Damaged coverings require an indepth inspection in that area. Note any damaged items or protective coverings on
Bill of Lading.
4.7.3
Notification. Immediately notify the shipper and any other responsible parties of
missing items and/or damage found to the unit or parts of the unit.
PREPARING UNIT FOR SERVICE
4.8.1
Warning Beacon(s). If warning beacons are supplied on unit, remove protective
tape covering from beacon mounting plate(s), remove beacon(s) from box(es),
and install beacon(s).
4.8.2
Air Cleaners. Remove plastic sheeting and duct tape from air intake of the
compressor and engine air cleaners.
4.8.3
Batteries. Ensure battery hold-down devices are secure. Coat battery posts with
petroleum jelly and install battery cables. Charge batteries if needed.
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Chapter 1
Section 4
4.8.4
Engine and Compressor. Perform the following:
a.
Remove sealing tape from end of engine exhaust pipe.
b.
Fill engine cooling system and radiator with coolant. Use coolant per
Detroit Diesel Operation and Maintenance Manual.
c.
Fill fuel tank with diesel fuel per Detroit Diesel Operation and
Maintenance Manual.
4.8.5
Control Panel. Remove cardboard from control panel.
4.8.6
Markings. Remove WARNING tag from ENGINE START switch on the control
panel. Perform Daily maintenance tasks as listed on the Preventive Maintenance
Schedule (Table 1.1) in Chapter 2 of this manual. Perform Pre-Start Procedures
and Operation Procedures in Section 2 of this chapter.
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Chapter 1
Section 5
Chapter 1, Section 5
Storage
5.1
5.2
PREPARING THE UNIT FOR STORAGE
5.1.1
When a unit is to be stored or removed from operation for a period of time,
special precautions should be taken to protect the interior and exterior of the air
start unit from rust accumulation and corrosion. The parts requiring attention and
the recommended preparations are given below. The compressor does not require
special preservation.
5.1.2
Rust and Corrosion Removal. It will be necessary to remove all rust or corrosion
completely from any exposed part before applying a rust-preventive compound.
Therefore, it is recommended that the unit be processed for storage as soon as
possible after removal from operation.
5.1.3
Storage Conditions. The unit should be stored in a building which is dry and can
be heated during the cold, wet weather season. Moisture-absorbing chemicals are
available commercially for use when excessive dampness prevails in the storage
area.
TEMPORARY STORAGE (30 DAYS OR LESS)
5.2.1
To protect the unit for 30 days or less, proceed as follows:
a.
Drain the engine crankcase.
b.
Fill the crankcase to the proper level with the recommended viscosity and
grade of oil.
c.
Fill the fuel tank with the recommended grade of fuel oil. Operate the
engine for 2 minutes in the UNLOAD mode.
Note:
Note:
CD295
4327
Do not drain the fuel system or the crankcase after this run.
d.
Check and service the air cleaners, if required, as outlined in Chapter 2.
e.
If freezing weather is expected during the storage period, add an ethyleneglycol–based antifreeze solution in accordance with the manufacturer’s
recommendations.
If an antifreeze solution is not to be used during this storage period, the
coolant system should be flushed with a good rust inhibitor to prevent rusting
of the outside diameter of the cylinder liners.
1-5-1
Orig
Chapter 1
Section 5
f.
5.2.2
5.3
Returning to Service. Prepared in this manner, the unit can be returned to service
in a short time by removing all sealing material and checking the engine coolant,
fuel oil, lubricating oil, and compressor oil.
EXTENDED STORAGE (MORE THAN 30 DAYS)
5.3.1
To prepare the unit for extended storage (more than 30 days), perform the
following procedures:
a.
Drain the cooling system and flush with clean, soft water. Refill with clean,
soft water and add a rust inhibitor to the cooling system.
b.
Remove, check, and recondition the injectors, if necessary, to ensure they
will be ready to operate when the engine is restored to service.
c.
Reinstall the injectors, time them, and adjust the exhaust valve clearance.
d.
Circulate the coolant by operating the engine until normal operating
temperature 160–185 °F (71–85 °C) is reached.
e.
Stop the engine.
f.
Drain the engine crankcase, then reinstall and tighten the drain plug. Install
new lubricating oil filter elements and gaskets.
g.
Fill the crankcase to the proper level with a 30-weight preservative lubricating oil MIL-L-21260C, Grade 2.
h.
Drain the fuel tank. Refill with enough clean No. 1 diesel fuel or pure
kerosene to permit the engine to operate for about ten minutes. If it isn’t
convenient to drain the fuel tank, use a separate portable supply of the
recommended fuel.
Note:
1-5-2
Orig
Seal all of the engine openings. The material used for this purpose must be
waterproof, vaporproof and possess sufficient physical strength to resist
puncture and damage from the expansion of entrapped air.
If the unit is stored where condensation of water in the fuel tank may be a
problem, add pure, waterless isopropyl alcohol (isopropanol) to the fuel at a
ratio of 1 pint (0.5 L)-to-125 gallons (473 L) of fuel or 0.010% by volume.
Where biological contamination of fuel may be a problem, add a biocide such
as Biobor JF, or equivalent, to the fuel. When using a biocide, follow the
manufacturer’s concentration recommendations and observe all cautions and
warnings.
i.
Drain and disassemble the fuel filter and strainer. Discard the used elements
and gaskets. Fill the cavity between the element and the shell with No. 1
diesel fuel or pure kerosene, and reinstall on the engine.
j.
Operate the engine for five minutes to circulate the clean fuel oil
throughout the fuel system.
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Chapter 1
Section 5
k.
Note:
Apply a nonfriction rust-preventive compound to all exposed parts. If
convenient, apply the rust preventive compound to the engine flywheel.
Do not apply oil, grease, or any wax base compound to the flywheel. The
cast iron will absorb these substances which can “sweat” out during
operation.
l.
Drain the engine cooling system.
m.
Remove and clean the battery and battery cables with a baking soda-water
solution and rinse with fresh water. Do not allow the soda solution to enter
the battery. Add distilled water to the electrolyte, if necessary, and fully
charge the battery. Store the battery in a cool (never below 32 °F or 0 °C)
dry place. Keep the battery fully charged and check the level and the
specific gravity of the electrolyte regularly.
n.
Insert heavy paper strips between the pulleys and belts to prevent sticking.
o.
Seal all unit openings, including the exhaust outlet, with moisture-resistant
tape. Use cardboard, plywood, or metal covers where practical.
p.
Clean and dry the exterior painted surfaces of the unit and protect with a
suitable liquid automobile body wax, a synthetic resin varnish, or a rustpreventive compound.
q.
Seal the air intake and discharge manifold to keep moisture out.
Do not put silica gel or any other foreign matter in the compressor
air inlet.
r.
5.3.2
Rotate compressor coupling several times each week.
Open-Weather Environment Storage. Open-weather environment storage is not
recommended. However, in some instances, open-weather environment storage
may be unavoidable. If units must be kept in an open-weather environment,
follow the preparation and storage instructions listed above. Protect the units
with quality, weather-resistant tarpaulins (or other suitable covers) arranged to
provide air circulation.
Do not use plastic sheeting for open weather environment storage.
Plastic is fine for enclosed, dry storage. When used in an open
weather environment, enough moisture can condense on the inside
of the plastic to rust ferrous metal surfaces and pit aluminum
surfaces. If a unit is stored in an open weather environment for an
extended period of time, severe corrosion damage can result.
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5.3.3
5.4
RESTORING A UNIT FROM EXTENDED STORAGE
5.4.1
1-5-4
Orig
Periodic Inspection. The stored unit should be inspected periodically. If there are
any indications of rust or corrosion, corrective steps must be taken to prevent
damage to the unit. Perform a complete inspection at the end of one year and
apply additional treatment as required.
Restoring the Unit to Service. To restore the unit to service after having been
stored for a long period, perform the following procedure:
a.
Remove the covers and tape from all of the openings of the engine, fuel
tank, and electrical equipment. Do not overlook the exhaust outlet.
b.
Wash the exterior of the unit to remove the rust preventive.
c.
Remove the rust preventive from the flywheel with brake cleaner.
d.
Remove the paper strips from between the pulleys and belts.
e.
Remove the drain plug and drain the preservative oil from the crankcase.
Reinstall the drain plug. Fill the crankcase to the proper level with the
recommended grade of lubrication oil.
f.
Fill the fuel tank with jet fuel.
g.
Close all of the drain cocks and fill the engine cooling system with clean
soft water and rust inhibitor. If the engine is to be exposed to freezing
temperatures, fill the cooling system with an ethylene glycol-based
antifreeze solution.
h.
Install and connect the battery.
i.
Service the air cleaners as outlined in Chapter 2, Section 3.
j.
Remove seals from the compressor air intake, compressor discharge and
manifold.
5.4.2
Starting the Unit. After all of the preparations have been completed, start the
engine. The small amount of rust preventive compound, which remains in the fuel
system, will cause a smoky exhaust for a few minutes.
Note:
Before subjecting the engine to a load or high speed, it is advisable to check
the engine tune-up.
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Chapter 2
TOC
Chapter 2
Maintenance
TABLE OF CONTENTS
Section/
Description
Paragraph
Page
1
1.1
1.2
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
How to Use the Preventive Maintenance Schedule . . . . . . . . . . . . . . . 2-1-1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
How to Use the Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2
Special Tools & Equipment (Engine Troubleshooting) . . . . . . . . . . . . . 2-2-3
Compressor and Air Pressure Regulation System Troubleshooting . . 2-2-10
Special Tools & Equipment (Compressor Troubleshooting) . . . . . . . . 2-2-11
Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
Special Tools & Equipment (Electrical Troubleshooting) . . . . . . . . . . 2-2-15
Electrical Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Trailer Chassis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Special Tools & Equipment (Trailer Chassis Troubleshooting) . . . . . . 2-2-19
3
3.1
3.2
3.3
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1
How to Use the Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . 2-3-2
List of Effective Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . 2-3-3
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Chapter 2
Section 1
Chapter 2, Section 1
Preventive Maintenance Schedule
1.1
INTRODUCTION
1.1.1
1.2
The Preventive Maintenance Schedule (Table 2.1) defines preventive maintenance tasks and time intervals between each task. This schedule applies to all TR/
TMD-150/180/250 Air Start Units. The following information will help you
utilize the preventive maintenance schedule.
HOW TO USE THE PREVENTIVE MAINTENANCE SCHEDULE
1.2.1
To use the preventive maintenance schedule, perform the following steps:
a.
Refer to Table 2.1. Scheduled maintenance tasks are listed in rows on the
far left side of the table. The frequency of each maintenance action is listed
in the columns at the top of the table. The hour frequency of preventive
maintenance is based on the time (hours) of actual operation of the
equipment. Refer to the unit hour meter to obtain hours of operation. The
calender schedule frequency of preventive maintenance is based on the
equipment being operated during a daily, weekly, monthly, or yearly period
of time as listed on the Preventive Maintenance Schedule. The equipment
owner should establish a preventive maintenance schedule based on his
equipment usage.
b.
Immediately to the right of the maintenance tasks are references to direct
the technician to the required maintenance procedures. The references are
defined as follows:
c.
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1.
MI 01001, MI 02001, etc.: Refer to Maintenance Instruction (MI)
“XXXXX” located in Chapter 2, Section 3.
2.
Vendor Material: Refer to the manufacturer’s data located behind Tab
A or B of Chapter 6 or manuals shipped under separate cover.
From the reference column, follow the row to the right until you encounter
an “X” in one of the blocks. Each “X” indicates a need for preventive
maintenance at specified time intervals.
2-1-1
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Chapter 2
Section 1
d.
At the “X,” move up the column up until you reach the recommended
frequency (i.e., the time interval between) of the maintenance action. Both
calendar-day and hourly time intervals are included.
To prevent damage to the unit, do not exceed the recommended time
intervals between inspection, servicing, or lubrication. Increase the
frequency of inspection, servicing, and lubrication if you operate
the unit in harsh environmental conditions.
e.
Perform the maintenance item at, or before expiration of, the indicated time
interval.
Ta ble 2 . 1
P R EV E N T I VE
M A I N T E N A N C E TAS K S
Pr ev e n t i v e M a i n t e n a n c e S ch e d u l e
REFERENC E
DAI LY WE E K LY M O N T H LY
(50 HR) ( 2 0 0 H R )
E V E RY 6 Y E A R LY
M O N T H S (100 0
( 5 0 0 H R ) HR)
Fluid Levels, Check
MI 99002A
X
Unit, Visual Inspection
MI 01002A
X
Air Delivery, Adjust Pressure
MI 11019A
X
Unloader Valve, Check Operation
MI 11001A
X
Tire Pressure, Check for TMD Air
Start Unit
MI 02004A
X
Fuel/Water Separator, Drain Water
MI 04004A
X
Compressor Discharge Coupling
Connectors for Proper Seal and
Torque
MI 11020A
X
Engine Oil and Filter, Change
MI 06002A
Vendor Material
Radiator Fan & Alternator Belts,
Check
Vendor Material
X
Alternator Wiring Harness &
Terminals, Inspect
Vendor Material
X
Fuel Strainer and Fuel Filter,
Change Elements
Vendor Material
X
Fuel Tank, Drain sediment &
moisture.
Vendor Material
X
Water Pump, Inspect Drain Hole
Vendor Material
X
2-1-2
Rev 1
X
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Ta ble 2 . 1
Pr ev e n t i v e M a i n t e n a n c e S ch e d u l e ( C o n t . )
P R EV E N T I V E
M A I N T E N A N C E TAS K S
Fuel Tank, Inspect Mounts, Lines
and Fittings for TMD Air Start Unit
REFERENC E
DAI LY WE E K LY M O N T H LY
(50 HR) ( 2 0 0 H R )
E V E RY 6 Y E A R LY
M O N TH S (100 0
(5 00 HR) HR)
MI 01003A
X
Vendor Material
X
MI 08003A
X
Exhaust Stack Rain Cap, Check
Operation
Vendor Material
X
Fuel/Water Separator, Change
(Option)
MI 04004
X
Emergency Shutdown, Test
MI 05010A
X
Radiator, Inspect and Clean Core
and Fins (Exterior).
Vendor Material
X
Thermostats and Seals, Check
Vendor Material
X
Cooling System, Clean, Flush, and
Replace Coolant.
Vendor Material
X
Crankcase Breathers and Tubes,
Clean
Vendor Material
X
Compressor Oil and Filter, Change
MI 11002A
Parking Brakes, Check and Adjust
for TMD Air Start Unit
MI 03001A
X
Wheel Bearings, Clean, Inspect, and
Repack for TMD Air Start Unit
MI 02005A
X
Engine Crankcase, Check Pressure
Vendor Material
X
Engine, Perform Tune-up
Vendor Material
X
Engine and Compressor Mounts,
Inspect
Vendor Material
X
Cooling System Hoses, Inspect
Engine and Compressor Air Filters,
Change Elements
X
* To be performed as required, as determined by engine performance.
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Chapter 2
Section 2
Chapter 2, Section 2
Troubleshooting
2.1
INTRODUCTION
2.1.1
2.2
This section provides information and troubleshooting tables for diagnosing and
correcting problems with the TR/TMD-150/180/250 air start units. The following
paragraphs will assist you in quickly locating the information needed to diagnose
malfunctions.
HOW TO USE THE TROUBLESHOOTING TABLES
2.2.1
Attempting tests or repairs to correct a problem without first analyzing its cause
can be very wasteful of time and resources. Before attempting tests or repairs:
a.
Note:
Determine which category below most closely relates to the problem your
unit is experiencing:
1.
Engine (Tables 2.2 through 2.6)
2.
Compressor (Tables 2.7 through 2.12)
3.
Electrical System (Tables 2.13 and 2.14)
4.
Trailer Chassis (Tables 2.15 and 2.16)
Because of the close relationship between some components of the engine
and electrical system, some troubleshooting procedures may cover similar
areas.
b.
Turn to the applicable procedure, and read the material carefully.
c.
If there is a fault indication on the Electronic Control Module (ECM), refer
to DDEC III/IV Troubleshooting Guide (under separate cover). Repair as
directed.
d.
Carefully perform the troubleshooting steps and recommended corrective
action.
2.2.2
The troubleshooting tables often reference other sections of this manual for
corrective actions or procedures. The references may be to another troubleshooting table, the DDEC III/IV Troubleshooting Guide (under separate cover), a
Maintenance Instruction (MI XXXXX), or to the manufacturer’s manuals in
Chapter 6 or under separate cover of this manual.
2.2.3
If any corrective action reference requires contacting TUG Technologies Corporation, please follow these steps:
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Chapter 2
Section 2
a.
Ensure that all applicable steps of the troubleshooting chart(s) have been
executed.
b.
If the problem is engine-related, write down all parts type codes from the
decal affixed to the engine rocker cover.
c.
Obtain the air start unit serial number from the unit’s nameplate.
d.
Contact TUG Technologies Corporation at:
TUG Technologies Corporation
815 Allgood Road
Marietta, GA 30062
Phone (Outside Georgia): 800-989-8499
Phone (In Georgia): 770-422-7230 (Warranty Dept.)
FAX: 770-422-8730
2.3
ENGINE TROUBLESHOOTING
2.3.1
The information provided in the engine troubleshooting tables helps maintenance
personnel diagnose and correct engine problems. Four engine troubleshooting
tables are provided:
a.
Table 2.2 Engine Will Not Crank
b.
Table 2.3 Engine Cranks, But Will Not Start
c.
Table 2.4 Engine Starts, But Will Not Continue To Run
d.
Table 2.5 Malfunction Shutdowns
e.
Table 2.6 Abnormal Operation
2.3.2
Tables 2.2, 2.3, and 2.4 deal with engine starting problems. Table 2.5 addresses
malfunctions that trip protective circuits to stop the engine. Table 2.6 deals with
problems with engine performance.
2.3.3
To diagnose and correct engine problems:
a.
Determine which table applies to the engine problem.
b.
Refer to the applicable table.
Note:
The probable causes for engine problems are listed in descending order,
from “most likely” to “least likely” to occur.
c.
2-2-2
Rev 6
Read the data in the troubleshooting tables and perform the recommended
corrective actions.
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Chapter 2
Section 2
d.
2.4
Refer to DDEC III/IV Troubleshooting Guide (under separate cover of this
manual). Repair as directed.
SPECIAL TOOLS & EQUIPMENT (ENGINE TROUBLESHOOTING)
2.4.1
The following tools and equipment will be needed to complete all tests and
corrective actions prescribed by the engine troubleshooting tables:
a.
Catch pans or containers for draining oil and coolant
b.
Oil filter strap wrench
c.
Standard mechanic’s tool set
d.
Floor jack or hoist rated at 15,000 lb (6804 kg).
e.
Jack stands rated for at least 15,000 lb (6804 kg).
Ta ble 2 . 2
En g i n e W i l l N o t C r a n k
P ROB LE M
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1.
ENGINE FAULT INDICATION
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
ENGINE RUN/STOP SWITCH (S2)
NOT IN RUN
Move RUN/STOP switch (S2) to RUN.
3.
MODE SELECTOR SWITCH (S10)
NOT IN UNLOAD
Place the MODE SELECTOR switch (S10) in
UNLOAD.
4.
BATTERIES (BT1A, BT1B, BT2A,
BT2B) DISCHARGED (dead)
Charge, or replace batteries (BT1A, BT1B, BT2A,
BT2B) as needed.
5.
BATTERY CABLE TERMINALS (J1, Clean, tighten, or replace battery cable terminals
J2, J3, J4) LOOSE, CORRODED, OR (J1, J2, J3, J4) as needed.
DISCONNECTED
6.
DEFECTIVE FUSES (F1, F2, F3, F4) Replace fuses (F1, F2, F3, F4) as needed.
7.
LOOSE STARTER CONNECTIONS
Tighten connections.
8.
DEFECTIVE STARTER (B1)
Repair or replace starter (B1).
9.
DEFECTIVE ALTERNATOR (G1)
(batteries not charging/discharging)
OR VOLTMETER (M1)
Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, positively isolate faulty switch.
Repair or replace as needed.
10. DEFECTIVE ENGINE CRANK
SWITCH (S1) and/or ENGINE RUN/
STOP SWITCH (S2)
Refer to the Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate the faulty
switch. Repair or replace as needed.
11. WIRING OR CABLES DEFECTIVE
Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate faulty wiring or
cables. Repair or replace as needed.
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Section 2
Ta ble 2 . 2
En g i n e W i l l N o t C r a n k ( C o n t . )
P ROB LE M
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12. DEFECTIVE RELAY OR RELAYS
Refer to Electrical Troubleshooting Procedure,
(K1, K2, K5, K8, K9, K11, K12, K14, paragraph 2.9, to positively isolate faulty relay(s).
K15)
Repair or replace as necessary.
13. DEFECTIVE STARTER SOLENOID
(L1)
Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate faulty solenoid.
Repair or replace as necessary.
14. DEFECTIVE MODE SELECT
SWITCH (S10)
Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate faulty switch
(S10). Repair or replace as necessary.
15. INTERNAL ENGINE SEIZURE OR
COMPRESSOR SEIZURE
Set RUN/STOP switch (S2) to STOP and attempt
to rotate engine manually. To do this, apply a
socket and large breaker bar to crankshaft's snout
bolt and pull, or remove starter motor and
carefully pry on ring gear teeth with a pry bar.
Failure to achieve a complete revolution indicates
internal engine or compressor damage. Contact
TUG for repairs.
Ta ble 2 . 3
En g i n e C r a n k s , B u t W i l l N o t S t a r t
P ROB LE M
1.
ENGINE FAULT INDICATION
2.
DEFECTIVE FUSES (F1, F2, F3, F4) Replace defective fuses and attempt a start. If fuse
burns out, determine why and replace fuse prior to
attempting another engine start.
3.
EMERGENCY STOP SWITCH (S9)
IN WRONG POSITION
Check position of the Emergency Stop Switch
(S9). Reset as necessary.
4.
DEFECTIVE EMERGENCY STOP
RELAY (K9)
Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate the faulty relay.
Repair or replace as necessary.
5.
ENGINE OVERSPEED INDICATED
a. Defective ECM.
6.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
NO AIR
a. Clogged engine air intake filter.
2-2-4
Rev 6
S OL UTI ON
Service or replace filter.
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Chapter 2
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Ta ble 2 . 3
En g i n e C r a n k s , B u t W i l l N o t S t a r t ( C o n t . )
P ROB LE M
7.
8.
9.
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SLOW CRANKING
a. Low battery (BT1A, BT1B, BT2A,
BT2B) output.
Service and charge the batteries. Replace batteries
if damaged. Clean and tighten loose, dirty, or
corroded battery terminals. Repair or replace
damaged battery cables. Cold temperatures will
reduce battery output; if unit is equipped with a
battery heater, warm the batteries.
b. Loose starter connections or faulty
starter.
Clean and tighten any loose starter connections. If
engine still cranks slowly, remove and repair or
replace starter.
INSUFFICIENT FUEL
a. Engine fuel system has run dry.
Fill empty fuel tank and bleed any air from fuel
lines. Refer to the Detroit Diesel Series 60 Service
Manual (under separate cover), for fuel system
bleeding procedures.
b. Clogged primary or secondary fuel
filter.
(Some units are equipped with an optional fuel/
water separator in place of primary fuel filter.)
Replace clogged filter. Check fuel tank for
contamination. Drain and flush any debris or
contaminants. If unit is equipped with an optional
fuel/water separator, drain any water and
sediment.
c. Kinked or obstructed fuel lines.
Replace obstructed or kinked fuel lines. Prime fuel
system per the Detroit Diesel Series 60 Service
Manual (under separate cover).
d. Air leaks on suction side of the
pump.
Locate leaks and eliminate them. Prime fuel
system as per the Detroit Diesel Series 60 Service
Manual (under separate cover).
e. Faulty fuel pump.
Check fuel pump as per the Detroit Diesel Series
60 Service Manual (under separate cover). Repair
or replace the faulty fuel pump.
COLD ENGINE
a. Lube oil viscosity too heavy for
particular cold weather, causing slow
cranking.
Change oil to viscosity recommended for your
current temperatures. See MI 06002A. If
temperatures are below 5 °F (-15 °C), heat engine.
Coolant, oil, and battery heaters are available as
options.
b. Ether injection starting aid failure
(temperatures below 40 °F (4 °C).
(OPTIONAL)
Check for an empty ether cylinder. Check ether
delivery line for kinks, crimps, or breaks. Check
connecting fittings for leaks. Check solenoid valve
control circuit (including thermostatic switch) for
faults. (Thermostatic switch closes at 40 °F (4 °C)
or lower.)
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Ta ble 2 . 3
En g i n e C r a n k s , B u t W i l l N o t S t a r t ( C o n t . )
P ROB LE M
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10. LOW COMPRESSION
a. Improper exhaust valve clearance.
b.Internal engine damage.
Adjust exhaust valve clearance per the Detroit
Diesel Series 60 Service Manual (under separate
cover).
Check for burned or sticking exhaust valves, worn
or broken compression rings, leaking cylinder
head gasket, or malfunctioning blower. Check
engine components per inspection and diagnosis
procedures provided in the Detroit Diesel Series
60 Service Manual (under separate cover). Contact
TUG for engine repairs.
Ta bl e 2 . 4
En g i n e S t a r ts , B u t W i l l N o t C o n t i nu e t o R u n
P ROB LE M
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1.
ENGINE FAULT INDICATION.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
UNIT SAFETY CIRCUIT FAULT.
See if any safety circuit faults have been detected.
Repair any faults prior to making additional start
attempts. Refer to Table 2.4 Malfunction
Shutdowns.
Ta ble 2 . 5
M a l f u n c t i o n S h u t d ow n s
P ROB LE M
1.
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LOW OIL PRESSURE
a. Low oil crankcase level.
Replenish oil level per MI 06002A.
b. Improper lube oil viscosity.
Change oil. Use oil recommended by engine lube
oil specifications table in MI 06002A.
c. Defective engine lube oil pressure Check for wiring faults and repair as needed. Test
sensor (SE3), ECM, or fault in wiring. ECM and pressure sensor (SE3) and replace as
necessary.
d. Internal engine lube oil system
damage or malfunction.
2-2-6
Rev 6
Refer to the Detroit Diesel Series 60 Service
Manual (under separate cover), for
troubleshooting procedures. Contact TUG for
engine repairs.
CD295
Chapter 2
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Ta ble 2 . 5
M a l f u n c t i o n S h u t d ow n s ( C o n t . )
P ROB LE M
2.
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HIGH COOLANT TEMPERATURE
a. Fan belts slipping.
Adjust fan belt tension per the Detroit Diesel
Series 60 Service Manual (under separate cover).
b. Debris or dirt blocking radiator
airflow.
Check for and remove any large foreign objects on
radiator's exterior. Flush dirt and dust from
radiator’s core and its fins with low-pressure
water. Use mild detergent and a soft bristle brush
to remove any oily deposits.
c. Low coolant level.
Replenish coolant per MI 99002A.
d. Thermostat(s) inoperative.
Test and replace thermostat(s).
e. Leaking or collapsed coolant hoses. Replace faulty hoses.
f. Scale deposits in cooling system are Use a good cooling system cleaner to remove scale
and deposits from cooling system. Neutralize and
impeding heat transfer.
thoroughly flush system to eliminate both deposits
and corrosive cleaner. Use distilled or mineralized
water in a fresh coolant solution to minimize scale
deposits. Refer to the Detroit Diesel Series 60
Service Manual (under separate cover), for
detailed cleaning and flushing instructions.
g. Water pump worn or damaged.
Inspect and repair or replace damaged pump as per
the Detroit Diesel Series 60 Service Manual (under
separate cover).
h. Exhaust gases are leaking into
water jacket via cylinder head gasket
or via cracks in cylinder heads.
Remove radiator cap, start engine, and watch for
gas bubbles in coolant. If exhaust gas leakage is
detected, remove and inspect cylinder head for
cracks. Replace cylinder head gaskets as detailed
in the Detroit Diesel Series 60 Service Manual
(under separate cover).
i. Defective temperature sensor (SE4) Check for wiring faults and repair as needed. Test
ECM and temperature sensor (SE4) and replace as
or wiring, or a fault in the ECM.
necessary.
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Ta ble 2 . 5
M a l f u n c t i o n S h u t d ow n s ( C o n t . )
P ROB LE M
3.
4.
5.
LOW FUEL TANK LEVEL (Optional)
a. Fuel tank empty or low.
Fill fuel tank.
b. Fuel level switch (S8) or wiring
faulty.
Check wiring and repair as needed. Test switch.
Replace if faulty.
c. Defective fuel low level sensor
(SE1) or wiring, or a fault in the
ECM.
Check for wiring faults and repair as needed. Test
ECM and fuel low level sensor (SE1) and repair as
necessary.
d. Defective Low Fuel Relay K8.
Refer to Electrical Troubleshooting Procedure,
Paragraph 2.9, to positively isolate the faulty
relay. Repair or replace as necessary.
LOW COOLANT LEVEL
a. Coolant level low.
Check for a coolant level leak. Repair as
necessary. Refill engine with coolant.
b. Defective coolant level sensor
(LT1), wiring harness, or ECM.
Check for wiring faults. If no faults are
discovered, check sensor (LT1) and ECM
functions. Replace as necessary.
HIGH OIL TEMPERATURE
a. Mechanical defect in engine.
Troubleshoot engine.
b. Plugged lube oil cooler.
Remove and clean oil cooler core. See the Detroit
Diesel Series 60 Service Manual (under separate
cover).
Ta ble 2 . 6
Ab n o r m a l O p e r a t i o n
P ROB LE M
1.
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S OL UTI ON
ENGINE FAULT INDICATION
S OL UTI ON
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
CD295
4940
Chapter 2
Section 2
Ta ble 2 . 6
Ab n o r m a l O p e ra t i o n ( C o n t . )
P ROB LE M
2.
CD295
4327
S OL UTI ON
LACK OF POWER
a. High ambient air temperature.
At air inlet temperatures above 90 °F (32 °C), for
every 20 °F (11 °C) of inlet air temperature
increase, a 2% brake horsepower loss occurs.
Measure ambient temperature and determine if
high inlet temperature is the cause for power loss.
b. High altitude operation.
Increasing altitude decreases air density. This
causes an engine to lose horsepower. The
percentage of power lost is approximately 1% per
1000 feet, beginning at 3000 feet above sea level.
c. Insufficient fuel.
Perform fuel flow test described in the Detroit
Diesel Series 60 Service Manual (under separate
cover). If fuel flow is inadequate, refer to the NO
FUEL OR INSUFFICIENT FUEL table in the same
manual.
d. Insufficient air.
Inspect air filter for evidence that filter is plugged.
Inspect turbocharger compressor blades for
damage and freedom of movement. Clean ports if
they are over 50% plugged. Check exhaust back
pressure per the Detroit Diesel Series 60 Service
Manual (under separate cover). Clean, repair, or
replace faulty parts.
e. Faulty tune-up.
Check tune-up per the Detroit Diesel Series 60
Service Manual (under separate cover).
f. Improper gear train timing.
Check engine gear train timing per the Detroit
Diesel Series 60 Service Manual (under separate
cover). Adjust timing as needed.
g. Defective ECM.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2-2-9
Orig
Chapter 2
Section 2
Ta bl e 2 . 6
Ab n o r m a l O p e r a t i o n ( C o n t . )
P ROB LE M
3.
4.
S OL UTI ON
UNEVEN RUNNING OR
FREQUENT STALLING
a. Low coolant temperature—coolant
does not reach 165 °F (74 °C).
Check thermostats for proper operation per the
Detroit Diesel Series 60 Service Manual (under
separate cover). Inspect for leakage past
thermostat seals. Replace as needed.
b. Insufficient fuel.
Perform fuel flow test described in the Detroit
Diesel Series 60 Service Manual (under separate
cover). Refer to the troubleshooting chart, NO
FUEL OR INSUFFICIENT FUEL, for fault
analysis.
c. Faulty injectors.
Refer to the Detroit Diesel Series 60 Service
Manual (under separate cover) and perform
procedure to test for misfiring cylinder. Check
injector timing. Erratic operation can be caused by
injectors with leaking spray tips. Replace any
faulty injectors.
d. Low compression pressures.
Refer to the Detroit Diesel Series 60 Service
Manual (under separate cover) and perform
compression check procedure.
e. Defective ECM.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
DETONATION
a. Low coolant temperature.
See item 3.a. of this table.
Clean air box and drain tubes. Inspect and drain
b. Air box drain tubes plugged or
check valves stuck closed. Accumula- check valves as per the Detroit Diesel Series 60
Service Manual (under separate cover).
tions of foreign objects are being
ingested through cylinder intake
ports.
2.5
c. Faulty injectors.
See item 3.c. of this table.
d. Oil picked up by the airstream.
Inspect turbocharger compressor discharge for
evidence of an oil leak. Repair, rebuild, or replace
the leaking turbocharger.
e. Defective ECM.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
COMPRESSOR AND AIR PRESSURE REGULATION SYSTEM TROUBLESHOOTING
2.5.1
2-2-10
Rev 1
The information provided in the troubleshooting tables helps maintenance
personnel diagnose and correct problems with the compressor and air pressure
regulation system. Six troubleshooting tables are provided.
CD295
4940
Chapter 2
Section 2
2.5.2
a.
Table 2.7 Compressor High Discharge Air Temperature
b.
Table 2.8 Compressor Low Discharge Air Pressure
c.
Table 2.9 Compressor High Discharge Air Pressure
d.
Table 2.10 Compressor Malfunction Indicated
e.
Table 2.11 Compressor Oil Leaks
f.
Table 2.12 Compressor Manifold Pressure Safety Valve Opens
To diagnose and correct problems:
a.
Determine which table applies to the problem.
b.
Refer to the applicable table.
Note:
2.6
The probable causes for compressor problems are listed in descending
order, from “most likely” to “least likely” to occur.
c.
Read the data in the troubleshooting tables, and perform the recommended
corrective actions.
d.
Refer to DDEC III/IV Troubleshooting Guide (under separate cover). Repair
as directed.
SPECIAL TOOLS & EQUIPMENT (COMPRESSOR TROUBLESHOOTING)
2.6.1
The following tools and equipment will be needed to complete all tests and
corrective actions prescribed by the troubleshooting tables:
a.
Catch pans or containers for draining oil
b.
Oil filter strap wrench
c.
Standard mechanic’s toolkit
Ta ble 2 . 7
CD295
4327
Co m p r e s s o r H i g h D i s ch a rg e A i r Te m p e r a t u r e
P ROB LE M
S OL UTI ON
1.
UNIT FAULT INDICATION.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
DISCHARGE PRESSURE TOO
HIGH FOR ALTITUDE OF
OPERATION
Adjust discharge pressure regulators as per MI
11019A.
3.
INACCURATE DISCHARGE AIR
TEMPERATURE
Check discharge air temperature with a calibrated
gauge.
2-2-11
Orig
Chapter 2
Section 2
Ta ble 2 . 7
Co m p r e s s o r H i g h D i s ch a rg e A i r Te m p e r a t u r e ( C o n t . )
P ROB LE M
4.
RESTRICTED COMPRESSOR AIR
INLET PASSAGE
Check filter restriction indicators for evidence of
clogged filter elements. Check for damaged inlet
air breathers. Ensure no foreign objects or
materials are blocking blower inlets.
5.
EXCESS COMPRESSOR ROTOR
DISCHARGE END CLEARANCE
Call TUG for repairs.
6.
COMPRESSOR ROTORS OUT OF
TIME AND CONTACTING
Call TUG for repairs.
7.
COMPRESSOR OIL LEVEL TOO
LOW
Service compressor oil per MI 99002A.
Ta ble 2 . 8
2-2-12
Rev 6
S OL UTI ON
Co m p r e s s o r L ow D i s ch a rg e A i r P r e s s u r e i n J e t S t a r t o r A i r
Pa ck s M o d e
P ROB LE M
S OL UTI ON
1.
UNIT FAULT INDICATION.
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
REGULATOR IMPROPERLY
ADJUSTED
Adjust regulators per MI 11019A.
3.
LEAK IN PIPING OR LOOSE,
LEAKING AIR HOSE
Repair or replace piping, hoses, and fittings as
needed.
4.
REGULATOR MALFUNCTIONING
Replace regulator. See Chapter 3, Section 2.
5.
INACCURATE DELIVERY AIR
PRESSURE GAUGE READING
Check gauge reading with a calibrated gauge.
6.
RESTRICTED COMPRESSOR
INLETS
Check compressor air filter for evidence of
clogged filters. Replace clogged filters per MI
08003A. Inspect compressor inlets for
obstructions.
7.
RESTRICTION OR LEAK IN AIR
CONTROL CIRCUIT LINES FROM
DISCHARGE MANIFOLD TO
UNLOADER VALVE
Inspect lines for leaks, cracks, kinks, dents, or
crimps. Eliminate leaks at fittings. Repair or
replace damaged line. Refer to MI 11020A for
compressor discharge coupling tie rod torque
specifications.
8.
IMPROPERLY ADJUSTED ENGINE Call TUG Service Department.
SPEED
9.
JET START SOLENOID NOT
ENERGIZED OR STUCK IN VENT
POSITION
Check electrical connections between mode
selection switch (S10) and solenoid valve.
CD295
Chapter 2
Section 2
Ta ble 2 . 9
Co m p r e s s o r H i g h D i s ch a rg e A i r P r e s s u r e i n J e t S t a r t o r
Air Pa cks Mo de
P ROB LE M
S OL UTI ON
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
1.
UNIT FAULT INDICATION
2.
RESTRICTION OR LEAKS IN
Find and eliminate leaks. Replace kinked, cracked,
SENSING LINE FROM DISCHARGE or dented sensing line.
AIR MANIFOLD TO REGULATORS
3.
LEAKING OR MALFUNCTIONING
SOLENOID VALVES
Replace faulty valve. See Chapter 3, Section 2.
4.
IMPROPERLY ADJUSTED ENGINE
SPEED CONTROL
Call TUG Service Department.
5.
UNSTABLE AIR PRESSURE IN JET
START OR AIR PACKS MODE
a. Moisture or foreign matter in air
regulation system lines or components.
Disassembly piping as necessary and clean or
replace.
Ta ble 2 . 1 0 C o m p r e s s o r M a l f u n c t i o n I n d i c a t e d
P ROB LE M
1.
UNIT FAULT INDICATION
2.
COMPRESSOR LOW OIL
PRESSURE
3.
CD295
S OL UTI ON
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
a. Low lube oil level.
Replenish compressor oil per MI 99002A (Table
2).
b. Compressor oil filter clogged.
Change compressor oil and filter per MI 11002A.
c. Internal compressor damage.
Call TUG Services for repairs.
d. Oil pressure switch (S5 and SE5)
faulty.
Replace oil pressure switch (S5 and SE5).
COMPRESSOR HIGH DISCHARGE
AIR TEMPERATURE
a. Discharge air temperature high.
Refer to Table 2.6.
b. Compressor discharge air temperature switch (S4) faulty.
Replace compressor discharge air temperature
switch (S4).
2-2-13
Rev 6
Chapter 2
Section 2
Ta ble 2 . 1 0 C o m p r e s s o r M a l f u n c t i o n I n d i c a t e d ( C o n t . )
P ROB LE M
4.
S OL UTI ON
COMPRESSOR HIGH OIL TEMPERATURE
a. Compressor oil cooler fins dirty or
obstructed.
Remove airflow obstructions from cooler fins.
Clean cooler exterior with low-pressure water. Use
a mild detergent and a soft bristle brush if needed
to remove oily deposits.
b. Internal compressor damage.
Call TUG Services for repairs.
c. Faulty oil temperature switch (S3,
S6).
Replace defective switch (S3, S6).
d. Compressor oil hose, oil cooler
internally clogged or faulty thermostatic bypass valve.
Replace.
e. Oil filter clogged.
Replace.
Ta ble 2 . 1 1 C o m p r e s s o r O i l L e a k s
P ROB LE M
S OL UTI ON
1.
OIL LEVEL IS TOO HIGH
Drain oil until it is approximately halfway up
sightglass. (See MI 11002A.)
2.
LOOSE OIL HOSE FITTINGS
Tighten fittings.
3.
OIL FILTER IS LOOSE
Tighten filter.
4.
INTERNAL COMPRESSOR SEALS
ARE DAMAGED
Call TUG Services for repairs.
Ta ble 2 . 1 2 C o m p r e s s o r D i s ch a rg e M a n i fo l d S a fe t y Va l v e O p e n s
P ROB LE M
2.7
S OL UTI ON
1.
SAFETY VALVE IS FAULTY
Ensure the safety valve opens at 52 psig (359
kPag). Replace the valve if it opens above or
below 52 psig (359 kPag).
2.
HIGH DISCHARGE PRESSURE
Refer to Table 2.8.
ELECTRICAL SYSTEM TROUBLESHOOTING
2.7.1
2-2-14
Rev 6
Troubleshooting Tables. Tables 2.13 and 2.14 deal with the possible types of
electrical system malfunctions. In both tables, the probable causes are listed
along with their suggested remedies from most likely to least likely. For help in
locating electrical components, refer to TUG Air Start Control Circuits with
DDEC IV Engine Schematic and see tables in Chapter 4, Section 4, Group 8.
CD295
Chapter 2
Section 2
2.8
SPECIAL TOOLS & EQUIPMENT (ELECTRICAL TROUBLESHOOTING)
2.8.1
2.9
A high-impedance volt-ohm-meter (20,000 ohms/volt or higher) can perform the
voltage and resistance checks used to isolate electrical system faults. Jumper
wires, alligator clips, and similar test probe attachments make it easier to perform
circuit tests.
ELECTRICAL TROUBLESHOOTING PROCEDURE
2.9.1
Visual Indications. The air start unit is equipped with malfunction sensing and
indicating circuits. Before beginning electrical tests, check malfunction indicator
lamps for clues as to which circuit is faulty. This may reduce the time necessary
to isolate faults.
2.9.2
Fault Isolation Techniques. Use the following universal fault isolation techniques
with the unit's electrical schematic to minimize the time needed to locate
electrical system faults:
a.
CD295
Half-Split Method. The quickest way to locate an unknown fault in a circuit
is the half-split method. To employ the half-split method, you must know
the fault exists in a particular circuit or current path. This method is most
often used for voltage checks but may also be used for continuity checks
and may be applied to isolate short circuits. The steps for DC voltage
checks are as follows:
1.
Set multimeter to DC volts. If using an analog (dial and needle)-type
meter, choose the voltage range that will register the desired voltage
near the middle of the scale. (For instance, to test for 12 VDC, select
the 24 or 25 VDC scale. To test for 24 VDC, select the 50-VDC
scale.)
2.
Connect the negative (-) test lead to the ground of the circuit being
tested. (Refer to the unit's schematic to identify connection.)
3.
Apply operating voltage to the circuit.
4.
Pick a point near middle of the circuit and test for the desired voltage.
5.
If the desired voltage is observed, the fault lies between the selected
point and the circuit's ground. If no voltage is observed, the fault lies
between the tested point and the DC voltage source.
6.
Test a point in the middle of the circuit's faulty section.
7.
Repeat steps (5) and (6) until a point is found beyond which no
voltage is present. This is the site of the circuit's fault.
2-2-15
Rev 6
Chapter 2
Section 2
b.
Backtrack Method. Use the backtrack method when it is impractical to use
the half-split method. To perform the backtrack method:
1.
Perform steps (1) through (3) of the half-split method.
2.
Test for voltage at the positive terminal of the malfunctioning device.
If the desired voltage is present, the device is faulty.
3.
If no voltage is present, test the circuit at the next connection toward
the voltage source. Repeat the test at each succeeding connection
until voltage is observed. The fault will lie at the point where that
occurs or between that point and the last point tested.
Ta ble 2 . 1 3 S t a r t i n g S y s t e m M a l f u n c t i o n s
P ROB LE M
S OL UTI ON
1.
ENGINE FAULT INDICATION
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
ENGINE WILL NOT CRANK
a. MODE SELECTOR switch (S10) is Place switch S10 in UNLOAD or replace it if it's
defective.
not in UNLOAD or it is defective.
b. Batteries (BT1A, BT1B, BT2A,
BT2B) are discharged.
Charge or replace battery.
c. Battery cables (J1, J2, J3, J4) are
loose or corroded.
Tighten or clean batteries and cable terminals.
d. Starter connections loose or dirty.
Clean connections with solvent and tighten as
needed.
e. Defective fuses (F1, F2, F3, F4).
Check fuses and replace as necessary; wait one
minute to see if fuses burn out again. If fuses burn
out, a short circuit exists that must be found and
repaired. If fuses are okay, attempt another start.
f. Defective Starter Solenoid (L1).
Replace Starter solenoid (L1).
g. Defective relay(s) (K1, K2, K5, K8, Refer to Electrical Troubleshooting Procedure,
paragraph 2.9, to positively isolate faulty relay(s).
K9, K11, K12, K14, K15).
Repair or replace as necessary.
2-2-16
Rev 1
h. Broken or loose wire in cranking
faulty.
Tighten connections and/or repair broken wire.
i. ENGINE CRANK switch S14
faulty.
Replace Crank switch (S1).
j. RUN/STOP Switch (S1) faulty.
Replace switch S11.
CD295
4940
Chapter 2
Section 2
Ta ble 2 . 1 3 S t a r t i n g S y s t e m M a l f u n c t i o n s ( C o n t . )
P ROB LE M
2.
S OL UTI ON
ENGINE WILL NOT CRANK (Cont.)
Replace relay (K1).
k. Engine running indication and
crank disconnect relay (K1) defective.
2.
l. Starter (B1) faulty.
Replace starter (B1).
m. Voltmeter (M1) faulty.
Replace Voltmeter (M1).
ENGINE CRANKS, WON'T START
a. Batteries are weak (cranking speed
is too slow).
Charge or replace battery.
b. Cool-down relay (TD1) is faulty.
Replace relay TD4.
c. Defective fuses (F1, F2, F3, F4).
Replace fuses and attempt another start. If fuse
burns out again, halt all start attempts and
determine cause.
d. Broken or loose wire in run circuit. Tighten connections and/or repair broken wire.
CD295
4327
e. Engine Run Relay (K2) defective.
Replace relay (K2).
f. RUN/STOP switch (S1) faulty.
Replace switch (S1).
g. TROUBLE RESET switch (S15)
faulty.
Replace switch (S15).
h. Problems with engine fuel.
Repair as required.
i. Defective Emergency Stop Relay
(K9).
Replace relay (K9).
j. Defective Emergency Stop Switch
(S9).
Replace switch (S9).
k. Defective ECM or wiring harness.
Check wiring harness and repair or replace as
necessary. Refer to DDEC III/IV Troubleshooting
Guide (under separate cover) for checkout of
ECM. Repair as directed.
l. Attempt start input missing.
Check for 24 volts at plug P-2, pin #P2-V on solid
state module. 24 volts is applied when engine is
cranked only.
2-2-17
Orig
Chapter 2
Section 2
Ta ble 2 . 1 3 S t a r t i n g S y s t e m M a l f u n c t i o n s ( C o n t . )
P ROB LE M
3.
S OL UTI ON
ENGINE STARTS, THEN DIES
a. Fuel pressure switch (SE3) is
faulty.
Replace fuel pressure switch (SE3).
b. Engine run relays (K1, K2) faulty.
Replace relays (K1, K2).
c. Broken or loose wire in run circuit. Tighten connections or repair broken wire.
d. Problems with engine fuel or
governor system.
Repair or replace.
e. Engine/Compressor Safety Circuit
Active.
Check Engine/Compressor Safety circuits. If any
circuit is triggered, investigate and repair cause
before attempting another engine start.
f. Defective wiring harness.
Check the wiring harness and repair or replace as
necessary. Refer to DDEC III/IV Troubleshooting
Guide (under separate cover) for checkout of the
ECM. Repair as directed.
Ta ble 2 . 1 4 B a t t e r y C h a rg i n g S y s t e m M a l f u n c t i o n s
2-2-18
Rev 1
P ROB LE M
S OL UTI ON
1.
ENGINE FAULT INDICATION
Refer to DDEC III/IV Troubleshooting Guide
(under separate cover). Repair as directed.
2.
ALTERNATOR BELT SLIPPING
Adjust alternator belt tension as per the Detroit
Diesel Series 60 Service Manual (under separate
cover).
3.
ALTERNATOR (G1) NOT
Repair or replace alternator (G1).
CHARGING (INTERNAL WEAR OR
DAMAGE)
4.
BATTERY CABLES (J1, J2, J3, J4)
LOOSE OR CORRODED
Tighten or clean batteries and cable terminals.
5.
LEAKAGE BETWEEN BATTERY
TERMINALS DUE TO DIRT ON
BATTERY CASE
Clean battery case.
6.
BATTERY PLATES AND/OR CASE
DAMAGED
Replace batteries (BT1A, BT1B, BT2A, BT2B).
7.
ALTERNATOR (G1) VOLTAGE IS
TOO HIGH. BATTERY
ELECTROLYTE IS BOILING
Repair or replace alternator (G1).
CD295
4940
Chapter 2
Section 2
2.10 TRAILER CHASSIS TROUBLESHOOTING
2.10.1 Applicability. These troubleshooting tables apply only to TMD-150/180/250
(trailer-mounted) air start units.
2.10.2 The information provided in the troubleshooting tables helps maintenance
personnel diagnose and correct problems with the air start unit trailer chassis.
Table 2.15 lists problems that may be experienced while towing the trailer. Table
2.16 lists problems that could occur with the trailer parking brakes.
2.11 SPECIAL TOOLS & EQUIPMENT (TRAILER CHASSIS TROUBLESHOOTING)
2.11.1 A standard mechanic's tool set is required. The following support equipment is
also required:
a.
Vehicle jack rated to support at least 15,000 lb (6,810 kg)
b.
Vehicle jackstands rated to support at least 15,000 lb (6,810 kg)
Ta ble 2 . 1 5 Tow i n g D i f f i c u lt i e s
P ROB LE M
1.
S OL UTI ON
TRAILER PULLS TO ONE SIDE
a. Tire air pressure low.
Inflate tires to 100 psi (689 kPa) and examine for
punctures and leaks. Repair any punctures or
leaks, or replace tire.
b. Brakes grabbing on one side:
2.
CD295
4327
(1) Brake shoes are unevenly
adjusted.
Adjust brake shoes as per MI 03001A.
(2) Brake shoes are improperly
installed.
Inspect brake shoes per MI 03001A. Replace any
worn out shoes and ensure that all shoes and
hardware are properly installed. Inspect wheel
brake cylinders for leaks and shoe linings for
brake fluid or grease contamination. If
contaminated, eliminate source of contamination
and replace any contaminated brake shoes.
c. Wheel bearing binding or seized.
Inspect wheel bearings. Replace any damaged
wheel bearings. Lubricate and install wheel
bearings and new grease seal per MI 02005A.
d. Axle bent.
Inspect axle carefully for bends or damage to
spindle. Replace damaged or bent axle assembly.
TRAILER DIFFICULT TO TURN
a. Tire pressure low.
Inflate tires to 100 psi (689 kPa).
b. Front axle steering hub assembly
dry.
Lubricate front axle steering hub assembly.
2-2-19
Orig
Chapter 2
Section 2
Ta ble 2 . 1 6 Pa r k i n g B r a k e s W i l l N o t H o l d
1.
P ROB LE M
S OL UTI ON
BRAKE SHOES ARE WORN.
Adjust brakes. See MI 03001A. Adjust hand brake
linkage.
If degree of slope is greater than 10° the
unit parking brake will not hold. Chock
both rear wheels.
2.
2-2-20
Rev 1
Degree of slope is too steep for unit
brakes to hold.
Chock both rear wheels.
CD295
4940
Chapter 2
Section 3
Chapter 2, Section 3
Maintenance Instructions
3.1
INTRODUCTION
3.1.1
A Maintenance Instruction (MI) provides information for servicing and
maintaining the TR/TMD-150/180/250 air start units. The following information
will assist you in using the maintenance instructions and allow you to service and
maintain your unit.
3.1.2
The numbering system used for these maintenance instructions is based on the
following:
Example:
MI 01001
a.
The initials MI stand for Maintenance Instruction.
b.
The first two numbers refer to the assigned category: 01 for Body/Chassis.
This category is assigned by TUG Technologies Corporation and consists of
the following codes:
01 BODY/CHASSIS
02 DRIVE TRAIN
03 BRAKES
04 FUEL SYSTEM
05 GOVERNORS
06 LUBRICATION SYSTEM
07 COOLING SYSTEM
08 INTAKE/EXHAUST SYSTEM
09 ELECTRICAL SYSTEM
10 GENERATOR
11 COMPRESSOR
99 MISCELLANEOUS
c.
CD295
The remaining numbers are sequential and allow for as many maintenance
instructions per category, as required.
2-3-1
Rev 6
Chapter 2
Section 3
3.2
HOW TO USE THE MAINTENANCE INSTRUCTIONS
3.2.1
In order to use the MI sheets, perform the following steps:
a.
Look up the required MI on the List of Effective Maintenance Instructions
(Table 2.17).
b.
To the right of the desired Maintenance Task is the Maintenance Instruction
Number. All MIs are in sequential order as they pertain to this unit.
c.
Turn to the desired MI. Verify that the MI reflects your particular piece of
equipment.
d.
Remove MI sheet(s). Each MI lists tools, equipment, and materials needed
to complete the maintenance task. Gather all necessary tools, equipment,
and materials and follow instructions on sheet(s) to perform the maintenance task.
Note:
If an office copier is available, make copies of the Maintenance Instruction
pages, and return the original pages to your technical manual. This will
ensure that needed maintenance information will still be available, despite
loss or damage to sheets used at the unit.
e.
2-3-2
Orig
After the maintenance task is complete, return MI sheet(s) to the technical
manual.
CD295
4327
Chapter 2
Section 3
3.3
LIST OF EFFECTIVE MAINTENANCE INSTRUCTIONS
3.3.1
A list of all MIs included in this manual can be found using Table 2.17.
Ta ble 2 . 1 7 L i s t o f E f fe c t i v e M a i n t e n a n c e I n s t r u c t i o n s
M A I NT EN AN CE TAS K
M I N O.
PAGE
Unit, Visual Inspection
MI 01002A
2-3-5
Fuel Tank, Inspect Mounts, Lines, and Fittings for TR/TMD-150/180/250 Air
Start Unit
MI 01003A
2-3-7
Tire Pressure, Check for TMD-150/180/250 Air Start Unit
MI 02004A
2-3-9
Wheel Bearings, Clean, Inspect, and Repack for TMD-150/180/250 Air Start
Unit
MI 02005A
2-3-11
Parking Brake, Check and Adjust for TMD-150/180/250 Air Start Unit
MI 03001A
2-3-15
Fuel/Water Separator, Drain Water
MI 04004A
2-3-21
Fuel Filter/Water Separator, Change Element
MI 04005A
2-3-23
Engine Oil and Filter, Change
MI 06002A
2-3-25
Engine and Compressor Air Filters, Change Elements
MI 08003A
2-3-31
Unloader Valve, Check Operation
MI 11001A
2-3-35
Compressor Oil and Filter, Change
MI 11002A
2-3-37
Compressor Gaskets, Replace
MI 11017A
2-3-43
Air Delivery, Adjust Pressure
MI 11019A
2-3-45
Compressor Discharge Coupling, Check
MI 11020A
2-3-47
Compressor Air Safety Valve, Adjust Pressure Relief Setting
MI 11021A
2-3-49
Fluid Levels, Check
MI 99002A
2-3-53
CD295
2-3-3
Rev 6
Chapter 2
Section 3
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CD295
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Chapter 2
Section 3
MI 01002A
MAINTENANCE INSTRUCTION 01002A
TECHNICAL PROCEDURES
UNIT, VISUAL INSPECTION
Total Number of Pages in this MI is 2.
1.
2.
TOOLS/EQUIPMENT:
a.
Flashlight
b.
Clean rag
MATERIALS:
None required.
3.
CD295
4327
PROCEDURE:
a.
Set the parking brake and chock the trailer’s wheels.
b.
Inspect the trailer and the unit’s exteriors for cleanliness, damage, and
general condition.
c.
Inspect the fuel lines and fuel system components. Note their general
condition, and look for fuel leaks.
d.
Inspect the oil lines and oil system components. Note their general condition,
and look for leaks.
e.
Inspect the air delivery hoses for wear, cracks, and splits.
f.
Check the turbocharger mounting flange, connections, and oil lines for leaks.
g.
Correct and record any discrepancies.
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Chapter 2
Section 3
MI 01002A
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CD295
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Chapter 2
Section 3
MI 01003A
MAINTENANCE INSTRUCTION 01003A
TECHNICAL PROCEDURES
FUEL TANK, INSPECT MOUNTS, LINES, AND FITTINGS
FOR TMD AIR START UNIT
Total Number of Pages in this MI is 2.
1.
2.
TOOLS/EQUIPMENT:
a.
Standard mechanic's hand tool set
b.
Clean rag
MATERIALS:
None required.
3.
CD295
4327
PROCEDURE:
a.
Set the parking brake.
b.
Inspect the fuel tank mounts for general condition, cracks, chafing, and
tightness. Tighten the mounts, as required.
c.
Check the general condition of the fuel lines and fittings at the tank. Look
for leaks. Tighten any lines and wipe up any fuel accumulations, as required.
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Chapter 2
Section 3
MI 01003A
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CD295
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Chapter 2
Section 3
MI 02004A
MAINTENANCE INSTRUCTION 02004A
TECHNICAL PROCEDURES
TIRE PRESSURE, CHECK
FOR TR/TMD AIR START UNIT
Total Number of Pages in this MI is 2.
1.
TOOLS/EQUIPMENT:
Tire pressure gauge
2.
MATERIALS:
Shop air, if required
3.
PROCEDURE:
Note:
CD295
4327
Do not check the tire pressure immediately after extensive road travel. Road
friction will have raised the tires’ temperature and pressure. Check the tire
pressure when the tires are cold.
a.
Apply the parking brake.
b.
Check the tire pressure. Proper tire pressure is 100 psig (689 kPag).
c.
Inflate or deflate the tires to their proper pressures, as required. Use lowpressure shop air to inflate the tires, if it’s required.
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Chapter 2
Section 3
MI 02004A
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CD295
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Chapter 2
Section 3
MI 02005A
MAINTENANCE INSTRUCTION 02005A
TECHNICAL PROCEDURES
WHEEL BEARINGS, CLEAN, INSPECT, AND REPACK
FOR TMD AIR START UNIT
Total Number of Pages in this MI is 4.
1.
2.
3.
TOOLS/EQUIPMENT:
a.
Hydraulic jack, lifting capacity greater than 15,000 lb (6,810 kg)
b.
Jackstands, supporting capacity greater than 15,000 lb (6,810 kg)
c.
Standard mechanic’s hand tool set
d.
Bucket or pail
e.
Clean rag
MATERIAL:
a.
Grease seal (replacement)
b.
Solvent, cleaning - diesel fuel, Varsol, or equivalent
c.
Grease - NGLI #2, or equivalent
PROCEDURE:
Always use lifting equipment, supports, and chains with a minimum
capacity of one and a half times the weight of the object being lifted
or supported. Otherwise, fatal or severe injury to personnel or
damage to equipment may occur.
Note:
CD295
4327
a.
Chock the trailer’s wheels and loosen, but do not remove the trailer wheels’
lug nuts.
b.
Place a warning tag on the unit’s control panel stating: “Unit Out of
Service.”
Ensure the parking brake is released.
2-3-11
Orig
Chapter 2
Section 3
MI 02005A
c.
(Trailer-mounted units only) Jack the unit up by its axles, and support it with
jack stands or supports rated for at least 15,000 lb (6,810 kg).
Do not work beneath a unit or vehicle that is supported only by
jacks. Make sure the unit is stable and firmly supported on stands
before proceeding underneath it. Personnel under a falling unit
would sustain severe or fatal crushing injuries.
d.
Refer to Figure 1. Remove the trailer wheel’s lug nuts (1) and wheel (2).
e.
Loosen and remove the wheel spindle grease cap (3).
f.
Remove the cotter pin (4), spindle nut (5), and washer (6).
g.
Dislodge the outer wheel bearing (7) by rocking the brake drum (8) (rear
wheels) or wheel spider (front wheels). Remove the outer wheel bearing (7).
h.
Carefully remove the brake drum (8) or wheel spider from the wheel spindle.
i.
Pry the grease seal (9) out of the brake drum (8) or wheel spider. Discard any
grease seal with a bent shell or damaged seal lip.
j.
Remove the inner wheel bearing (10) from the brake drum (8) or wheel
spider.
k.
To remove the old grease, clean the bearings and brake drum or wheel spider
with solvent.
l.
Examine the bearing rollers for grooves, brinelling, pitting, or flat spots.
Examine the roller cage assemblies and look for dents or damage. Replace
any bearing that has sustained any of those.
m.
Examine the bearing races in the cleaned brake drums and wheel spiders for
pitting, grooving, dimples, or dents. Replace any bearing races exhibiting
those types of damage:
n.
2-3-12
Orig
1.
Place the brake drum (8) or wheel spider on a solid surface. Ensure that
the race to be removed is facing downward.
2.
Using a brass drift and a hammer against the back of the race, drive it
out of the brake drum or wheel spider.
3.
Clean the race seat with solvent.
4.
Press a new race into the seat, or drive it into a seated position with the
brass drift and hammer.
Pack the center cavities of the brake drum (8) or wheel spider with clean
bearing grease.
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o.
CD295
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Chapter 2
Section 3
MI 02005A
Pack the inner bearing (10) with grease until clean grease is forced out
around the rollers.
p.
Install the inner bearing (10) into the brake drum (8) or wheel spider, then
retain them by installing the grease seal (9). (Grease seals may be pressed
into place or driven into place with a wooden block and a hammer.)
q.
(Rear wheels only) Clean the inside of the brake drum (8) with solvent to
remove all traces of oil and grease from the braking surface.
r.
Carefully install the brake drum (8) or wheel spider over the spindle and
brake shoes (11).
s.
Pack the outer wheel bearing (7) with grease until clean grease is forced out
around the rollers.
t.
Install the outer wheel bearing (7), washer (6), and spindle nut (5).
u.
Tighten and lock the spindle nut (5) as follows:
1.
Tighten the spindle nut (5) to 15 ft-lb (20.34 Nm) while turning the
brake drum (8) or wheel spider to fully seat the bearings.
2.
Loosen the spindle nut (5) just enough to allow the drum to be easily
rotated. Push and pull in and out on the drum or spider to detect any
axial play. Tighten the spindle nut enough to eliminate any axial play
but not enough to bind the bearings.
v.
Install the castellated spindle nut retainers with new cotter pin (4).
w.
Place the grease cap (3) in position, and tap it with a rawhide or plastic
mallet to seat it.
x.
Install the wheel (2) and lug nut (1).
y.
Lower the unit to ground. Tighten its wheels’ lug nuts (1), using a criss-cross
pattern.
z.
Remove the warning tag and return the unit to service.
2-3-13
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Chapter 2
Section 3
MI 02005A
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lug Nuts
Wheel
Grease Cap
Cotter Pin
Spindle Nut
Washer
Outer Bearing
Brake Drum or Wheel Spider
Grease Seal
Inner Bearing
Brake Shoes
Figure 1
2-3-14
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Hub and Drum Assembly
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Chapter 2
Section 3
MI 03001A
MAINTENANCE INSTRUCTION 03001A
TECHNICAL PROCEDURES
PARKING BRAKES, CHECK AND ADJUST
Total Number of Pages in this MI is 6.
1.
2.
TOOLS/EQUIPMENT:
a.
Standard mechanic's hand tool set
b.
Jack or hoist, rated at 15,000 lb (6,804 kg)
c.
Jack stands rated for at least 15,000 lb (6,804 kg)
d.
Brake adjustment tool (optional)
MATERIAL:
None required
3.
ROUTINE ADJUSTMENT PROCEDURE:
Routine adjustment may be done by the operator, by tightening or loosening the
knurled knob on the parking brake operating handle:
a.
Chock wheels to immobilize unit.
b.
Release parking brake to relieve tension on brake rods.
c.
To increase tension on parking brakes, turn knurled adjustment knob (1,
Figure 1) on parking brake handle (2) clockwise.
d.
To decrease tension on parking brakes, turn knurled adjustment knob on
parking brake handle counterclockwise.
e.
Operate brake handle two or three times to verify proper tension and
operation.
Too much tension will make the handle hard to operate. Too little
tension will not fully engage the brakes. Brake handle should firmly
engage the brakes without excessive effort.
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2-3-15
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Chapter 2
Section 3
MI 03001A
f.
4.
Once proper operation is restored, remove the wheel chocks, and return the
unit to operation. If proper operation cannot be restored, a major adjustment
is needed.
MAJOR ADJUSTMENT PROCEDURES:
Major adjustment to the parking brakes is needed when routine adjustment fails to
restore proper brake operation, or when brake components (brake shoes, linkage,
or operating handle) have been replaced.
Major adjustment to the brakes requires that the brakes be
released. Before working under the unit, chock the wheels to
immobilize the unit.
To ensure maximum brake holding power, make equal adjustments
to both cable assemblies.
a.
2-3-16
Orig
Major Adjustment:
1.
Chock wheels to immobilize unit.
2.
Jack up rear axle and support with jack stands rated for at least 6,750
lb (3,062 kg).
3.
Disengage parking brake and turn knurled adjustment knob (1, Figure
1) fully counterclockwise to loosen linkage.
4.
Adjust rod (4) by loosening jamnuts on clevis (3) and rotating rod in or
out of clevises (3). Tighten jamnuts when complete.
5.
Ensure rods (5) are adjusted equally. Tighten jamnuts on clevises (3).
6.
Perform routine adjustment procedure to finalize brake linkage
adjustment.
7.
Verify adjustment by operating parking brake handle. Handle operation
should be smooth, and should engage brakes without excessive force.
Test brake engagement by attempting to rotate tires while the unit is on
stands. Make fine adjustment, if necessary, per Routine Adjustment
procedure.
8.
Re-check brake operation.
CD295
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Chapter 2
Section 3
MI 03001A
Remove unit from jack stands. If adjustment is satisfactory, return the
unit to service.
9.
3
5
5
3
1
2
4
3
1.
2.
3.
4.
5.
3
Knurled Adjustment Knob
Parking Brake Handle
Clevis
Control Rod
Control Rod
Figure 1
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3
8
Parking Brake Adjustment
2-3-17
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Chapter 2
Section 3
MI 03001A
1.
2.
3.
4.
Backing Plate
Shoe Adjustment Slot
Adjustment Tool
Slot Plug
Figure 2
2-3-18
Orig
Brake Shoe Adjustment
CD295
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Chapter 2
Section 3
MI 03001A
b.
Brake Shoe Adjustment (at axle):
1.
Chock front axle wheels.
Never work beneath a unit or vehicle that is supported only by
jacks. Make sure unit is stable and firmly supported on stands
before working under it. A falling unit would likely cause severe or
fatal crushing injuries.
CD295
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2.
Jack up rear axle and support with jack stands rated for at least 6,750
lb (3,062 kg).
3.
Remove cotter pin from clevis pin. Remove clevis pin from clevises
(Figure 1, item 3).
4.
Remove plug (Figure 2, item 4) from forward brakeshoe adjustment
slot (item 2) in backing plate (item 1).
5.
Insert brake adjusting tool (item 3), or large flat-tip screwdriver blade
through forward adjustment slot (item 2) to contact teeth of brake
adjuster screw.
6.
Pry upward on adjuster teeth to tighten brake shoes.
7.
Spin wheel assembly of adjusted brake shoes to detect drag.
8.
Repeat steps (6) and (7) until brake shoes begin to drag slightly, then
loosen adjustment (pry downward on adjuster) just enough to eliminate
most of the drag.
9.
Replace plug (item 4) into adjustment slot in backing plate.
10.
Repeat steps (3) through (9) for opposite rear wheel.
11.
Adjust cable per Cable Adjustment Procedure.
12.
Jack unit up off stands, remove jack stands, and lower unit to ground.
13.
Return unit to service.
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Chapter 2
Section 3
MI 03001A
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Chapter 2
Section 3
MI 04004A
MAINTENANCE INSTRUCTION 04004A
TECHNICAL PROCEDURES
FUEL/WATER SEPARATOR, DRAIN WATER
Effectivity: P/N 1000FG (Optional Equipment)
Total Number of Pages in this MI is 2.
1.
2.
TOOLS/EQUIPMENT:
a.
Container
b.
Clean rag
MATERIAL:
None required
3.
PROCEDURE:
The optional fuel/water separator may be used upstream of the standard primary
fuel filter or in place of it. Drain the fuel/water separator as follows:
CD295
4327
a.
Apply the parking brake.
b.
Place a warning tag on the control panel stating: “Unit Out of Service.”
c.
Check the clear collection bowl (Figure 1, item 1) on the bottom of the fuel/
water separator assembly for accumulated water once a day. If water is
present, perform the following steps:
1.
Place a small container below the fuel/water separator to catch
drainage.
2.
Open the fuel/water separator assembly drain (item 2). Drain any water
into the container. Close the drain (item 2) once all water has been
removed.
3.
Properly dispose of all fluids.
d.
Wipe any excess or spilled fuel from around the fuel filter/water separator.
e.
Start the unit, and check it for leaks.
f.
Remove the warning tag, and return the unit to service.
2-3-21
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Chapter 2
Section 3
MI 04004A
1.
2.
Bowl
Drain
Figure 1
2-3-22
Orig
Fuel Filter/Water Separator (Option)
CD295
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Chapter 2
Section 3
MI 04005A
MAINTENANCE INSTRUCTION 04005A
TECHNICAL PROCEDURES
FUEL FILTER/WATER SEPARATOR, CHANGE ELEMENT
P/N 1000FG (Optional Equipment)
Total Number of Pages in this MI is 2.
1.
2.
TOOLS/EQUIPMENT:
a.
Container suitable for collecting small quantities of spilled fuel
b.
Clean rag
MATERIAL:
Filter element, P/N 2020SM-OR (1000FG)
3.
CD295
5395
PROCEDURE:
a.
Apply the parking brake.
b.
Place a warning tag on the control panel stating: “Unit Out of Service.”
c.
Disconnect batteries.
d.
Place a container under the separator to collect spilled fuel.
e.
Turn the T-handle (Figure 1, item 1) counterclockwise and remove the Thandle and lid (item 2).
f.
Remove the element (item 5) by slowly pulling the molded handle upward
with a turning motion.
g.
Insert the replacement element over the center tube (item 6) with a
downward, turning motion.
h.
Pour clean diesel fuel into the filter/separator housing (item 4) until it is full.
i.
Inspect the lid seal (item 3) and replace it if necessary.
j.
Replace the lid (item 2) and hand-tighten the T-handle (item 1).
k.
Remove the fuel container and wipe up any excess fuel.
l.
Start the engine, and check the filter/separator assembly for leaks.
m.
Remove the warning tag and return the unit to service.
2-3-23
Rev 2
Chapter 2
Section 3
MI 04005A
1.
2.
3.
4.
5.
6.
T-Handle
Lid
Seal
Housing
Element
Center Tube
Figure 1
2-3-24
Orig
Fuel Filter/Water Separator (Option)
CD295
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Chapter 2
Section 3
MI 06002A
MAINTENANCE INSTRUCTION 06002A
TECHNICAL PROCEDURES
ENGINE OIL AND FILTER, CHANGE
Total Number of Pages in this MI is 6.
4.
5.
6.
TOOLS/EQUIPMENT:
a.
Filter wrench (strap-type or equivalent)
b.
Standard automotive mechanics hand toolset
c.
Container, capable of holding 10 gallons (37.9 L)
MATERIAL:
a.
Filter, engine oil, P/N 23518480, 2 required.
b.
Oil, 35 quarts (33 L) (see Viscosity Selection Chart)
REFERENCE:
Detroit Diesel Series 60 Service Manual (under separate cover).
7.
PROCEDURE:
Hot oil can burn severely. When performing an oil change, protect
yourself by wearing rubber gloves.
Note:
CD295
5395
Change the engine oil just after the engine has been operated and is still
warm so that most contaminants are still suspended in the oil and will be
carried out with it as it drains.
a.
Park the unit on level ground.
b.
Apply the parking brake.
c.
Place a warning tag on the control panel that states: “Unit Out of Service.”
d.
Disconnect batteries.
2-3-25
Rev 2
Chapter 2
Section 3
MI 06002A
1.
2.
3.
Figure 1
2-3-26
Rev 2
Plug
Engine Oil Filter(s)
Engine Oil Fill
Engine Oil Component Assembly
e.
Place a catch pan below the remote drain plug (Figure 1, item 1).
f.
Loosen and remove the oil drain plug.
g.
Allow the oil to drain. Clean drain plug threads, and once all oil has drained
out, install and tighten the oil drain plug.
h.
Place the catch pan beneath the engine’s oil filters (item 2).
CD295
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i.
Chapter 2
Section 3
MI 06002A
Use a filter strap wrench to loosen both oil filters. Remove the filters and
drain it into the catch pan.
j.
Inspect the filter mounting base assembly for deposits and dirt. Scrape off
any deposits on the filter gasket’s sealing surface. Wipe the filter gasket’s
sealing surface clean.
k.
Apply a thin coat of oil to a new filter gasket.
l.
Carefully thread the new oil filter (item 2) onto the mounting base assembly
and tighten it hand tight. (Always refer to the filter manufacturer's instructions for proper installation.)
Do not mix oils from different refiners or of different viscosities,
and avoid overfilling the engine crankcase. Check the crankcase oil
level frequently while filling to prevent overfilling. Oil leaks and
bearing damage could result if the crankcase is overfilled.
CD295
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m.
Fill the engine crankcase through the filler neck (item 3) with approximately
35 quarts (33 liters) of an oil listed in the engine lube oil viscosity chart
(Table 1). Check the crankcase oil level by using the dipstick (FIGURE
REFERENCE).
n.
Start the unit, and check the engine’s oil filter for leakage. If needed, use a
strap wrench to tighten the filter element just enough to stop any leaks.
o.
Remove the warning tag, and return the unit to service.
2-3-27
Orig
Chapter 2
Section 3
MI 06002A
Ta ble 1
En g i n e L u b e O i l S p e c i f i c a t i o n s
Note:
Use API CD-II or military specification MIL-L-2104E or MIL-L-46167 oils with
sulfated ash less than 1.0%. (The military specifications listed represent the
current specifications including revisions at the time of this publication.) Use
only oils meeting these specifications. The oils may be used at temperatures
lower than those shown in the table if the engine is equipped with a coolant
heater that will preheat the engine before starting.
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Chapter 2
Section 3
MI 06002A
Ta ble 1
CD295
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En g i n e L u b e O i l S p e c i f i c a t i o n s ( C o n t . )
OIL
CO M M E N T S
1.
GRADE 40 MILL-2104E API
SERVICE CD-II
Preferred oil for normal temperatures and cold temperatures where auxiliary
heating aids are available and cold weather starting is not a problem.
2.
GRADE 50 MILL-2104E API
SERVICE CD-II
For continuous high temperature operation above 100 oF (38 oC) ambient or
200 oF (93 oC) engine coolant out.
3.
GRADE 30 MILL-2104E API
SERVICE CD-II
Use when starting is a problem due to ambient temperature falling below 50 oF
(10 oC), but continuous high ambient temperature does not exceed 80 oF (27 oC)
or 195 oF (91 oC) engine coolant out.
4.
GRADE 15W/40
MIL-L-2104E API
SERVICE
CD-II
Use below 32 oF (0 oC) ambient when starting is a problem due to temperature
and where starting aids are not available; or at very cold temperatures [0 to
-25 oF (-18 to -32 oC) ambient]. May be used above 32 oF (0 oC) where daily
temperatures exceed 32 oF (0 oC) only for short periods.
5.
GRADE 0W-20
MIL-L-46167 API
SERVICE CD-II
Use only at extreme cold temperatures [0 to -60 oF (-18 to -51 oC)]. Although
0W-20 oils have been used successfully in severe cold regions, Detroit Diesel
does not consider their use as desirable as the use of Grade 40, Grade 30, and
15W-40 oils with auxiliary heating aids. For this reason, 0W-20 oils should be
considered only where engine cranking is a severe problem and auxiliary
heating aids are not practical. Arctic fuels or jet fuels, other than JP4, are
recommended when operating with 0W-20 oils.
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Chapter 2
Section 3
MI 06002A
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Chapter 2
Section 3
MI 08003A
MAINTENANCE INSTRUCTION 08003A
TECHNICAL PROCEDURES
ENGINE AND COMPRESSOR AIR FILTERS, CHANGE ELEMENTS
Total Number of Pages in this MI is 4.
1.
TOOLS/EQUIPMENT:
Clean rag
2.
3.
MATERIAL:
a.
Engine air filter element, P/N P105695
b.
Compressor air filter elements (two) P/N 484P
PROCEDURE:
a.
Engine Air Filter Replacement.
1.
Set the parking brake, and chock the wheels.
2.
Place a warning tag on the control panel stating: “Unit Out of Service.”
3.
Release the three retaining levers (Figure 1, item 1) that secure the air
filter element to its housing.
4.
Remove the air filter element (item 2).
Do not allow any debris or dirt to enter the turbocharger inlet.
Ingested dirt or debris can damage the turbocharger and the
engine.
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5.
Remove any accumulated dirt or debris from the filter housing. Wipe
the housing clean to ensure there is an airtight seal with the new filter
element.
6.
Install the new filter element (item 2).
2-3-31
Orig
Chapter 2
Section 3
MI 08003A
1.
2.
Figure 1
b.
Air Cleaner Assembly
Filter Element
Engine Air Cleaner Assembly
Compressor Intake Filter Replacement.
1.
Loosen and remove the tie-rod wing nuts.
2.
Lift the element (Figure 2, item 2) out of the base.
Do not allow any debris or dirt to enter the turbocharger inlet.
Ingested dirt or debris can damage the turbocharger and the
engine.
2-3-32
Orig
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3.
1.
2.
Chapter 2
Section 3
MI 08003A
Remove any accumulated dirt or debris from the filter housings. Wipe
the housings clean to ensure airtight seals with the new filter elements.
4.
Install new filter element (item 2) with its retaining hardware (item 1).
5.
Remove the warning tag, and return the unit to service.
Retaining Nut
Air Filter Element
Figure 2
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Compressor Air Cleaner Assembly
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Chapter 2
Section 3
MI 08003A
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2-3-34
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CD295
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Chapter 2
Section 3
MI 11001A
MAINTENANCE INSTRUCTION 11001A
TECHNICAL PROCEDURES
UNLOADER VALVE, CHECK OPERATION
Total Number of Pages in this MI is 2.
1.
TOOLS/EQUIPMENT:
None required.
2.
MATERIALS:
MI 11019A
3.
PROCEDURES:
Check the unloader valve’s operation by performing the following steps:
CD295
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a.
Set the parking brake, and chock the wheels.
b.
Start the unit and allow it to warm up as specified in the unit’s operating
procedures in Chapter 1, Section 2.
c.
Figure 1 illustrates how the unloader valve operates.
d.
At the unit’s control panel move the MODE SELECTOR switch from
UNLOAD to AIR PACKS mode. The unloader valve’s observer is looking for
the unloader shaft to move down, closing the valve (Figure 1, item 1). The
COMPRESSOR AIR PRESSURE gauge reading should indicate 24 psig (165
kPag).
e.
At the control panel, switch the MODE SELECTOR back to UNLOAD mode.
If it’s operating properly, the unloader valve plunger (item 1) will move
upward, returning to the open position, and all compressor discharge air will
exit through the air silencer. The COMPRESSOR AIR PRESSURE gauge
should indicate about 10 psig (69 kPag).
f.
At the control panel, switch the MODE SELECTOR back to JET START. The
unloader valve (item 1) should close completely. The COMPRESSOR AIR
PRESSURE gauge should indicate 42 psig (289 kPag).
g.
Refer to the air pressure regulator adjustment procedure MI 11019A if the
manifold discharge pressure deviates from the listed norms in any operating
mode.
2-3-35
Orig
Chapter 2
Section 3
MI 11001A
Figure 1
2-3-36
Orig
Unloader Valve
CD295
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Chapter 2
Section 3
MI 11002A
MAINTENANCE INSTRUCTION 11002A
TECHNICAL PROCEDURES
COMPRESSOR OIL AND FILTER, CHANGE
Total Number of Pages in this MI is 8.
1.
2.
3.
TOOLS/EQUIPMENT:
a.
Standard automotive mechanic’s hand toolset
b.
Strap wrench
c.
Drain pan 42 quarts (40 liters)
MATERIALS:
a.
Filter, oil P/N SH000001
b.
Oil, 40 quarts (37.85 liters) for 250 ppm units
40 quarts (37.85 liters) for 150 and 180 ppm units
PROCEDURE:
a.
Park the unit on a level surface.
b.
Apply the hand parking brake and chock wheels.
c.
Operate the unit until it reaches its normal operating temperature.
d.
Shut down unit.
e.
Place a warning tag on the unit’s start switch, advising that the unit must not
be started.
f.
Disconnect batteries.
g.
Place a pan or container under the compressor remote oil drain (Figure 2,
item 4).
h.
Remove the remote oil drain plug (Figure 1, item 3).
Hot oil can burn severely. When performing an oil change, protect
yourself by wearing rubber gloves.
CD295
5395
2-3-37
Rev 5
Chapter 2
Section 3
MI 11002A
i.
Allow the compressor oil to thoroughly drain. Clean the threads of the drain
plug, then install and tighten.
j.
Place the oil pan below the compressor lube oil filter (Figure 2, item 1).
k.
Loosen and remove the spin-on–type compressor lube oil filter. (Use a strap
wrench to loosen the filter.)
l.
Inspect the filter mounting base assembly. To provide a leak-free seal, the
sealing surface must be flat, smooth, and free of deposits. Scrape off any
deposits, and wipe the filter mounting base sealing surface clean.
Do not mix oils from different refiners or of different viscosities,
and avoid overfilling compressor sump. Check the sump oil level
frequently while filling the compressor to prevent overfilling it.
Gear and bearing damage could otherwise result.
2-3-38
Orig
m.
Coat the new filter gasket with a thin coat of clean oil.
n.
Screw a new filter onto the filter head assembly. Hand turn the filter until its
gasket contacts the filter mounting base, then tighten it an additional 1/2 to
3/4 turn.
o.
Fill the compressor through the fill tube (Figure 1, item 6) with an approved
lube oil selected from Table 1 and replace filler/breather cap (Figure 1, item
7).
p.
Check the compressor’s oil level on the sightglass (Figure 1, item 8). Ensure
that the oil is at the proper operating level.
q.
Start the unit. Check that the compressor oil pressure gauge reads from 15 to
45 psi (103 to 220 kPa) with the MODE SELECTOR switch in the JET
START position and no load on the unit. Operate the unit until it reaches its
normal operating temperature, and then check the compressor oil filter and
remote drain plug for leakage. If needed, tighten the filter element with a
strap wrench just enough to stop any leaks.
r.
Recheck the compressor oil level. Add oil as required.
s.
Place the MODE SELECT switch in UNLOAD. Shut down the unit or
continue operating it, as desired.
t.
Remove the warning tag from the unit’s start switch.
u.
Remove chocks from unit’s wheels.
v.
The unit is now ready for normal operation.
CD295
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Ta ble 1
Note:
Chapter 2
Section 3
MI 11002A
CO M P RE S S O R L U B E O I L V I S CO S I T Y S E L E C T I O N C H A RT
Refer to the table below to determine the proper oil viscosity grade (VG) and
oil type for operation in the specified ambient temperature ranges.
All of the oils listed in Table 1 have been approved by the compressor
manufacturer. However, for extended life of compressor, it is recommended
that it be replaced with Mobil SHC 626 oil the when oil is changed. Mobil
SHC 626 oil performs over the widest temperature range and provides
maximum and is the oil that TUG furnishes in the compressor. The
compressor oil needs to be changed after every 600 hours of operation or
once a year. This applies whether the oils used are mineral or synthetic.
Operating the compressor outside the proper range of temperatures for a
given oil can result in equipment damage.
CD295
2-3-39
Rev 6
Chapter 2
Section 3
MI 11002A
Ta ble 1
CO M P RE S S O R L U B E O I L V I S CO S I T Y S E L E C T I O N C H A RT
(Cont.)
R EF E RE NC E N U MB ER
MAKE
COLUMN 1
32 to 122 oF
(0 to 50 oC)
MINERAL OIL
ISO VG68
COLUMN 2
5 to 59 oF
(-15 to 15 oC)
MINERAL OIL
ISO VG32
Agip
DTE 68
Aral
Kosmol TL 68
Kosmol TL 32
AVIA
AVILUB Turbinoil C
AVILUB Turbinoil A
BP
Inergol TMB68
Caltex
Regal R&O 68
Castrol
Perfecto T 68
Chevron
CC Turbine Oil 68
DIRCO
TVA-68
TVA-32
Dubois Chemicals
MPO-20
MPO-10
Elf
TURBELF SA68
TURBELF SA32
Alphasyn T68
RS 68
Fina
Bakola 68
Bakola 32
Fuchs
Renolin DTA20
Renolin DTA10
Gulf
Harmony 68
Igol
Syntopress P 68
IP
Herzia Oil 68
Herzia Oil 32
LE Monolec
Turbine Oil 6403
Turbine Oil 6401
Liqui Moly
LM 900
DTE Heavy Medium
SHC 626
Muddex
Anderole 3068
Petrolube
Turbine Oil T 68
Shell
Turbo Oil T 68
Sovereign Lub
Omega 612, SAE 20
Turbine Oil T 32
Madrella Oil AS68
Omega 612, SAE 10
Syneco
Cleanair 680
Texaco
Regal Oil R&O 68
Trek
Turbine Oil 68
2-3-40
Orig
COLUMN 4
-40 to 122 oF
(-40 to 50 oC)
PAO
(SYNTHETIC)
Regal R&O 32
Esso
Mobil
COLUMN 3
-22 to 122 oF
(-30 to 50 oC)
PAO
(SYNTHETIC)
Regal Oil R&O 32
CD295
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Chapter 2
Section 3
MI 11002A
1.
2.
3.
4.
5.
6.
7.
8.
Compressor Oil Filter
Straight Adapter
Plug
Straight Adapter
Compressor Remote Drain Hose
Assembly
Compressor Sump/Breather/Fill
Standpipe
Push-on Breather/Filler
Sightglass
Figure 1
CD295
4327
Compressor Oil Component Assembly
2-3-41
Orig
Chapter 2
Section 3
MI 11002A
1.
2.
3.
4.
Figure 2
2-3-42
Rev 2
Compressor Oil Filter
Compressor Oil Sight Level
Compressor Oil Fill
Compressor Oil Drain
Compressor Fluid Level and Fill Locations
CD295
5395
Chapter 2
Section 3
MI 11017A
MAINTENANCE INSTRUCTION 11017A
TECHNICAL PROCEDURES
COMPRESSOR GASKETS, REPLACE
Total Number of Pages in this MI is 2.
1.
TOOLS/EQUIPMENT:
Standard automotive mechanic’s hand tool set
2.
MATERIAL:
Gaskets, P/N SD000006
3.
PROCEDURE:
Not available at time of printing.
CD295
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2-3-43
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Chapter 2
Section 3
MI 11017A
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2-3-44
Orig
CD295
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Chapter 2
Section 3
MI 11019A
MAINTENANCE INSTRUCTION 11019A
TECHNICAL PROCEDURES
AIR DELIVERY, ADJUST PRESSURE
Total Number of Pages in this MI is 2.
1.
TOOLS/EQUIPMENT:
Standard automotive mechanic’s hand tool set
2.
MATERIAL:
None required.
3.
PROCEDURE:
This procedure adjusts the control (pilot) air signal to desired levels in the AIR
PACKS and JET START modes of unit operation. The following adjustment
procedures can be performed most efficiently by one person. To perform the
adjustment, proceed as follows:
Note:
CD295
4327
Adjustment must be made with discharge air delivery valve(s) in the closed
position. This can be accomplished by using an air delivery hose with an
automatic shutoff aircraft connect nozzle.
a.
Set the parking brake, and chock the wheels.
b.
Place a warning tag on the control panel stating: “Unit Out of Service”.
c.
Start the unit, and allow to run in UNLOAD mode for at least 5 minutes to
warm up. Check that the tachometer on the unit’s Gauge and Meter Panel
shows the engine is idling at approximately 1100 rpm. The compressor
output pressure should be about 10 psi (69 kPa) while the engine is idling.
d.
Check all control air piping running from compressor discharge manifold to
the solenoid valves, the regulating valves and the unloader valve for air
leaks. Air leaks can be easily detected by applying soapy water to air line
fittings and joints. Bubbles indicate leaks that must be eliminated before
proceeding. Leaks can make it impossible to obtain proper discharge pressure
and hinder regulator response.
e.
Place the MODE SELECTOR switch in the AIR PACKS mode. If the
delivery pressure is not 24 psig (165 kPag), adjust the regulator valve
(Figure 1) by loosening the knob locking nut (2) and then slowly turning the
2-3-45
Orig
Chapter 2
Section 3
MI 11019A
regulator valve knob (1), either clockwise to raise discharge pressure or
counter clockwise to lower discharge pressure. After adjustment has been
made, tighten the knob locking nut (2).
f.
Place the MODE SELECTOR switch in the JET START mode. If the delivery
pressure is not 42 psig (290 kPag), adjust the regulator valve (Figure 1) by
loosening the knob locking nut (4) and then slowly turning the regulator
valve knob (3), either clockwise to raise discharge pressure or counter
clockwise to lower discharge pressure. After adjustment has been made,
tighten the knob locking nut (4).
g.
Place MODE SELECTOR switch in the UNLOAD mode and shut down unit.
h.
Stow air hose and remove wheel chocks.
i.
Remove warning tag from control panel.
Figure 1
2-3-46
Rev 2
Regulator/Solenoid Assembly
Typical Jet Start/Air Packs
CD295
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Chapter 2
Section 3
MI 11020A
MAINTENANCE INSTRUCTION 11020A
TECHNICAL PROCEDURES
COMPRESSOR DISCHARGE COUPLING, CHECK
(P/N 12970123)
Total Number of Pages in this MI is 2.
1.
2.
TOOLS/EQUIPMENT:
a.
Standard mechanic's hand tool set
b.
Heat resistant gloves
c.
Torque wrench
MATERIAL:
a.
3.
None required.
PROCEDURE TO ADJUST
Check compressor discharge coupling connector for proper seal and re-torque.
CD295
a.
Apply the parking brake.
b.
Place a warning tag on the control panel stating: “Unit Out of Service.”
c.
Check compressor discharge coupling connector (item 1, Figure 1) tie rod
bolts (item 2) for proper sealing torque, 75 ft/lb (111.6 kg/meter).
d.
Re-torque tie rod bolts (item 2) to 75 ft/lb (111.6 kg/meter). Tighten tie rod
bolts (item 2) in a "star" pattern. Do not allow the gaskets to extrude from
the sealing connection.
e.
Remove the warning tag and return the unit to service.
2-3-47
Rev 6
Chapter 2
Section 3
MI 11020A
1
1.
2.
Figure 1
2-3-48
Rev 6
2
Discharge Coupling
Connector
Tie Rod Bolts
Compressor Discharge Coupling
CD295
Chapter 2
Section 3
MI 11021A
MAINTENANCE INSTRUCTION 11021A
TECHNICAL PROCEDURES
COMPRESSOR AIR SAFETY VALVE, ADJUST PRESSURE RELIEF SETTING
Total Number of Pages in this MI is 4.
1.
2.
TOOLS/EQUIPMENT:
a.
3–6" opening pipe wrench
b.
Pliers
c.
Diagonal pliers (wire cutting)
d.
Standard screw driver
MATERIAL:
a.
3.
CD295
Loctite #262 or equal
PROCEDURE TO ADJUST
a.
Set the parking brake, and chock the wheels.
b.
Place a warning tag on the control panel stating: “Unit Out of Service.”
c.
Locate remote mounted safety valve.
d.
With diagonal pliers, cut safety seal (item 15) and discard.
e.
Remove both (2) nameplate screws (item 9) and retain for later use.
f.
Retain nameplate (item 13).
g.
With pipe wrench, turn spring cap (item 14) clockwise until threads on the
spring cap (item 14) are approximately 1/8" below the body of the valve
(item 3).
h.
Start air start unit and place into JET START mode.
i.
Ensure that the unit is at full speed and 42 psig discharge pressure with both
discharge valves partially open.
j.
Adjust JET START regulator adjustment handle (T handle) clockwise to
increase system pressure until safety valve begins to open. At this time,
record the maximum system pressure on the gauge.
2-3-49
Rev 6
Chapter 2
Section 3
MI 11021A
2-3-50
Orig
k.
If safety valve DID NOT OPEN and discharge pressure gauge reads approximately 55 psig OR HIGHER, then the safety valve needs readjustment to a
lower relief pressure. PROCEED TO STEPS (m) AND (n).
l.
If safety valve DID OPEN and the discharge pressure gauge reads approximately 45 psig OR LESS, then the safety valve needs readjustment to a
higher pressure. PROCEED TO STEPS (m) THEN (o).
m.
At this point, visually inspect the spring cap (item 14) to verify that it has
not come loose (rotated). If so, readjust (turn) spring cap (item 14) back to
its initial height.
n.
With pipe wrench, turn spring cap (item 14) counter clockwise approximately
1/4 turn. Repeat steps (i) through (o).
o.
With pipe wrench, turn spring cap (item 14) clockwise approximately 1/4
turn. Repeat steps (h) through (o).
p.
Repeat steps (n) or (o) (whichever applies) until safety valve barely opens
when both discharge valves are shut simultaneously, maximum discharge
pressure (pressure spike) reads approximately 45 to 50 psig, and engine
drops to idle speed.
q.
After step (p) is achieved, apply Loctite #262 thread locking compound to
both (2) nameplate screws (item 9).
r.
Install both (2) nameplate screws (item 9) through nameplate (item 13) and
into safety valve body. Note that both (2) nameplate screws (item 9) should
recess into the casting grooves of the spring cap (item 14).
s.
Install safety seal wire (item 15) through both (2) holes in the screw head of
both (2) nameplate screws (item 9). Insert loose end of safety seal wire (item
15) into the lead crimp end of the same safety seal wire (item 15). With
pliers, crimp safety seal wire (item 15) over the lead end.
t.
Apply Loctite #262 thread locking compound to both (2) nameplate screw
heads (item 9) for visual verification this procedure has been completed.
CD295
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Chapter 2
Section 3
MI 11021A
Figure 1
CD295
4327
Compressor Air Safety Valve
2-3-51
Orig
Chapter 2
Section 3
MI 11021A
This Page Intentionally Left Blank
2-3-52
Orig
CD295
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Chapter 2
Section 3
MI 99002A
MAINTENANCE INSTRUCTION 99002A
TECHNICAL PROCEDURES
FLUID LEVELS, CHECK
Total Number of Pages in this MI is 8.
1.
TOOLS/EQUIPMENT:
Clean rag
2.
MATERIAL:
As required. See specification page or procedural steps.
3.
REFERENCE:
Detroit Diesel Series 60 Service Manual (under separate cover).
4.
PROCEDURE:
Make all fluid level checks with the unit parked on level ground and the unit’s
parking brake set.
a.
b.
CD295
4327
Fuel Tank Level:
1.
Check the fuel tank’s level.
2.
Fill the tank as required through the fill tube (Figure 1, item 2) using
either Diesel Fuel Grade No. 1-D or Grade No. 2-D, as defined by
ASTM Designation D975 for diesel fuels or JET-A fuel. The temperature at the time of start determines the diesel fuel to be used. Use the
Diesel Fuel Specifications, Figure 2, to find the expected air temperature at the start time on the thermometer scale and the correct diesel
fuel on the right of scale.
Engine Oil Level:
1.
Locate the engine dipstick.
2.
Pull the engine’s dipstick out of its tube and wipe it clean.
2-3-53
Orig
Chapter 2
Section 3
MI 99002A
3.
Reinsert the dipstick and then withdraw it and check the oil level.
Overfilling the engine crankcase can result in oil leaks or bearing
damage. When adding oil, check the engine’s oil level frequently to
avoid overfilling it.
4.
c.
If the oil level is down to the ADD mark on the dipstick, add it through
the filler (Figure 1, item 4) enough to bring the level up to near the
FULL level. (See Table 1 for specifications.)
Compressor Lube Oil Level: Check the compressor lube oil level daily or
before operating the unit
1.
Locate the compressor sight level glass.
Overfilling the compressor sump can result in oil leaks or bearing
damage. When adding oil, check the compressor’s oil level
frequently to avoid overfilling it.
2.
d.
If the oil level is below the halfway point of the sightglass, add enough
oil through the oil fill (item 3) to bring the level up to the halfway
point on the sight level glass. (See Table 2 for specifications.)
Engine Coolant Level: Check the engine coolant level daily or before each
operation of the unit.
1.
Check the engine coolant temperature. If necessary, wait until the
coolant temperature drops below 200 o F (95 o C) before proceeding.
Escaping steam and hot coolant can cause severe burns. The cooling
system is pressurized. Never open a radiator cap when coolant is
hot, and use a cloth or wear a glove to handle a hot radiator
pressure cap. Ethylene glycol antifreeze is toxic and can irritate
skin. Wash any part of body that comes in contact with antifreeze
solution as soon as possible.
2.
Note:
2-3-54
Orig
Look into the upper radiator tank through the sight level glass. The
coolant level should fill the sight level glass. The coolant level should
just cover the sightglass, not fill the entire top tank. This is to allow
room for coolant expansion in the tank as it warms.
Some minor coolant loss due to thermal expansion after refilling the radiator
is normal. Very low coolant level (down to, or below, core tubes) indicates a
serious leak in the system that must be located and corrected.
CD295
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3.
4.
Chapter 2
Section 3
MI 99002A
If needed, remove radiator cap, prepare a coolant solution per Detroit
Diesel Series 60 Service Manual (under separate cover), Coolant
Solution Specifications. Add coolant solution as required to restore the
coolant level as in step 2 above.
If the coolant level was unusually low, refill the radiator at fill point
(item 1), then:
a.
Carefully inspect all cooling system hoses and connections for
leaks.
b.
Start the unit, allow it to reach normal operating temperature, and
inspect the cooling system again. Repair any leaks before
returning unit to service.
5.
Once the coolant level is satisfactory, replace and tighten the radiator
cap.
6.
Return the unit to service.
Figure 1
CD295
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Fluid Level and Fill Locations
2-3-55
Orig
Chapter 2
Section 3
MI 99002A
Figure 2
Note:
Diesel Fuel Specifications
At altitudes above 5,000 feet (1,500 meters) use Grade 1-D for all temperatures. If the engine is operated under “stand-by” conditions, use Grade 1-D
for all temperatures.
A fuel sulfur content of less than 0.5 percent is preferred to prevent higher
engine wear due to corrosive combustion products.
Excessive white smoke at startup could indicate a low cetane fuel.
Ensure that the cetane number is no less than 40 to assure satisfactory
starting and overall performance. At low temperatures and/or high altitude, a
cetane number of more than 45 is recommended.
The fuel’s cloud point needs to be at least 10 oF (6 oC) below the lowest
expected air temperature at the time of engine start. If the temperature is at
or near the cloud point, wax can separate from the fuel, plugging the fuel
filter.
2-3-56
Orig
CD295
4327
Chapter 2
Section 3
MI 99002A
Ta ble 1
EN G I N E L U B E O I L S P E C I F I C AT I O N S
Note:
Use API CD-II, military specifications, MIL-L-2104E or MIL-L-46167 as noted
with sulfated ash less than 1.0%. The military specifications listed represent the
current specifications at the time of this publication including revisions. Use only
oils meeting these specifications. The oils listed below may be used at temperatures lower than those shown if the engine is equipped with a coolant heater to
preheat the engine before starting. The oil specifications and recommendations
listed herein apply only to the TR/TMD-150/180/250 air start unit and do not
apply to any other application of the DDC 8V92 engine.
OIL
CD295
4327
CO M M E N T S
1.
GRADE 40 MILL-2104E API
SERVICE CD-II
Preferred oil for normal temperatures and cold temperatures where auxiliary
heating aids are available and cold weather starting is not a problem.
2.
GRADE 50 MILL-2104E API
SERVICE CD-II
For continuous high temperature operation above 100 oF (38 oC) ambient or
200 oF (93 oC) engine coolant out.
3.
GRADE 30 MILL-2104E API
SERVICE CD-II
Use when starting is a problem due to ambient temperature falling below 50 oF
(10 oC), but continuous high ambient temperature does not exceed 80 oF (27 oC)
or 195 oF (91 oC) engine coolant out.
4.
GRADE 15W/40
MIL-L-2104E API
SERVICE
CD-II
Use below 32 oF (0 oC) ambient when starting is a problem due to temperature
and where starting aids are not available; or at very cold temperatures [0 to
-25 oF (-18 to -32 oC) ambient]. May be used above 32 oF (0 oC) where daily
temperatures exceed 32 oF (0 oC) only for short periods.
5.
GRADE 0W-20
MIL-L-46167 API
SERVICE CD-II
Use only at extreme cold temperatures [0 to -60 oF (-18 to -51 oC)]. Although
0W-20 oils have been used successfully in severe cold regions, Detroit Diesel
does not consider their use as desirable as the use of Grade 40, Grade 30, and
15W-40 oils with auxiliary heating aids. For this reason, 0W-20 oils should be
considered only when engine cranking is a severe problem and auxiliary heating
aids are not practical. Arctic fuels or jet fuels, other than JP4, are recommended
when operating with 0W-20 oils.
2-3-57
Orig
Chapter 2
Section 3
MI 99002A
Ta ble 2
Note:
CO M P RE S S O R L U B E O I L V I S CO S I T Y S E L E C T I O N
Refer to the table below to determine the proper oil viscosity grade (VG) and
type as specified by the compressor manufacturer when operating the unit in
the ambient temperature ranges shown. However, for extended life of
compressor, replace the oil with Mobil SHC 626 oil. This is the oil that TUG
furnishes in the compressor. Mobil SHC 626 oil performs over the widest
temperature range and provides maximum protection.
Change the oil after every 600 hours operation or at least once a year,
regardless of whether mineral or synthetic oils are being used.
Operating the compressor outside the approved range of temperatures for
any given oil can damage the equipment.
2-3-58
Rev 6
CD295
Chapter 2
Section 3
Ta ble 2
CO M P RE S S O R L U B E O I L V I S CO S I T Y S E L E C T I O N ( C o n t . )
R EFE RE NC E NU MB ER
MAKE
COLUMN 1
32 to 122 oF
(0 to 50 oC)
MINERAL OIL
ISO VG68
COLUMN 2
5 to 59 oF
(-15 to 15 oC)
MINERAL OIL
ISO VG32
Agip
DTE 68
Aral
Kosmol TL 68
Kosmol TL 32
AVIA
AVILUB Turbinoil C
AVILUB Turbinoil A
BP
Inergol TMB68
Caltex
Regal R&O 68
Castrol
Perfecto T 68
Chevron
CC Turbine Oil 68
DIRCO
TVA-68
TVA-32
Dubois Chemicals
MPO-20
MPO-10
Elf
TURBELF SA68
TURBELF SA32
Alphasyn T68
RS 68
Fina
Bakola 68
Bakola 32
Fuchs
Renolin DTA20
Renolin DTA10
Gulf
Harmony 68
Igol
Syntopress P 68
IP
Herzia Oil 68
Herzia Oil 32
LE Monolec
Turbine Oil 6403
Turbine Oil 6401
Liqui Moly
LM 900
DTE Heavy Medium
SHC 626
Muddex
Anderole 3068
Petrolube
Turbine Oil T 68
Shell
Turbo Oil T 68
Sovereign Lub
Omega 612, SAE 20
Turbine Oil T 32
Madrella Oil AS68
Omega 612, SAE 10
Syneco
Cleanair 680
Texaco
Regal Oil R&O 68
Trek
Turbine Oil 68
CD295
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COLUMN 4
-40 to 122 oF
(-40 to 50 oC)
PAO
(SYNTHETIC)
Regal R&O 32
Esso
Mobil
COLUMN 3
-22 to 122 oF
(-30 to 50 oC)
PAO
(SYNTHETIC)
Regal Oil R&O 32
2-3-59
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Chapter 2
Section 3
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2-3-60
Orig
CD295
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Chapter 3
TOC
Chapter 3
Overhaul
TABLE OF CONTENTS
Section/
Description
Paragraph
Page
1
1.1
1.2
1.3
Overhaul Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Air Start Unit Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .‘3-1-1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
Preparation for Engine/Compressor Removal . . . . . . . . . . . . . . . . . . . 3-2-1
Engine/Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2
Engine/Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2
Installation and Reconnection of Other Equipment . . . . . . . . . . . . . . . 3-2-3
Removal of Air Start Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . 3-2-4
Installation of Air Start Pressure Regulator . . . . . . . . . . . . . . . . . . . . 3-2-4
Removal and Replacement of Air Solenoid Valves . . . . . . . . . . . . . . . 3-2-5
CD295
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3-TOC-i
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Chapter 3
TOC
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3-TOC-ii
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CD295
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Chapter 3
Section 1
Chapter 3, Section 1
Overhaul Data
1.1
1.2
AIR START UNIT OVERHAUL
1.1.1
The TR/TMD-150/180/250 Air Start Unit must be maintained by strict adherence
to the preventive maintenance schedule, and timely repair, and overhaul. Proper
servicing, maintenance, following manufacturer’s recommendations, and recordkeeping are important activities that establish the overhaul intervals.
1.1.2
TUG Technologies Corporation provides preventive maintenance recommendations in Chapter 2, Section 1, of this manual. Maintenance instructions provided
in Chapter 2, Section 3, detail how to perform maintenance on specific components or how to perform specific maintenance tasks. The troubleshooting tables in
Chapter 2, Section 2, are specific to this equipment and will assist the operator
and maintenance personnel in quickly isolating and correcting most common
malfunctions.
ENGINE
1.2.1
1.3
For engine maintenance and overhaul procedures, refer to the Detroit Diesel
Series 60 Service Manual located under separate cover of this manual.
AIR COMPRESSOR
1.3.1
CD295
For air compressor overhaul procedures, refer to the GHH-RAND Service Information located in Chapter 6, Tab A, of this manual.
3-1-1
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Chapter 3
Section 1
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Chapter 3
Section 2
Chapter 3, Section 2
Removal and Installation
2.1
GENERAL
2.1.1
2.2
The following procedures will assist the maintenance technician in removing and
replacing major items. Refer to the Maintenance Instructions in Chapter 2,
Section 3, of this manual for removal and replacement procedures for minor
items.
PREPARATION FOR ENGINE/COMPRESSOR REMOVAL
2.2.1
The engine and air compressor need to be removed as a single unit.
2.2.2
Enclosure Removal. Before attempting engine/compressor removal, remove the
unit’s enclosure to provide adequate access for a lifting crane. Disconnect and
label wiring, air lines, hoses, and piping, leading to or from the engine and
compressor, and remove the enclosure as follows:
Remove the battery’s ground cable before removing the ungrounded
cable to prevent electrical sparks and possible burns. Remove the
ground cable from its grounding point before removing the ground
cable from the battery.
CD295
4940
a.
Tag and disconnect the battery cables. Ensure that the battery ground cable is
disconnected first.
b.
Drain the engine’s coolant.
c.
Disconnect and remove the radiator hoses from the engine and the radiator.
d.
Tag and disconnect all pressure lines and electrical wires leading to and from
the Gauge and Meter panel. Cap any disconnected pressure lines to prevent
contamination from entering them.
e.
Tag and disconnect all fuel lines, drain lines, oil cooler hoses, drain hoses,
fuel, and any other lines or hoses that would interfere with the enclosure’s
removal or with engine/compressor removal. Cap any disconnected fuel and
oil lines to prevent contamination from entering them.
f.
Tag and disconnect the electrical wiring between engine/compressor and
enclosure, including wiring that runs to the Control and Indicator panel.
g.
Remove the exhaust piping between the engine manifold and the muffler.
3-2-1
Rev 1
Chapter 3
Section 2
h.
Remove the air piping between the unloader valve and the silencer.
i.
Remove the air discharge piping and flange, with shutoff valves, by
unbolting the pipe flange.
j.
Remove the discharge manifold coupling and tie-rods. Separate the discharge
manifold from the compressor outlet. Tag the bolts by type and location so
that they are easily reinstalled.
k.
Remove the bolts that secure the enclosure to the frame. Tag the bolts by
type and location so that they are easily reinstalled.
Always use lifting equipment, supports, and chains with a rated
capacity of at least one and a half times that of the object being
lifted or supported to avoid injury to personnel or damage to the
equipment.
l.
2.3
Carefully lift the enclosure from the unit.
ENGINE/COMPRESSOR REMOVAL
Always use lifting equipment, supports, and chains with a rated
capacity of at least one and a half times that of the object being
lifted or supported to avoid injury to personnel or damage to the
equipment.
2.3.1
2.4
a.
Remove the mounting bolts that secure the engine and compressor to the
frame.
b.
Attach a chain and hoist to the front engine lift ring and the two compressor
lifting eyes.
c.
Take the slack out of the chain. Check the hoist connections.
d.
Carefully lift the engine/compressor assembly from the frame. Once it is
clear, move it to a location suitable for separating the engine from the
compressor.
ENGINE/COMPRESSOR INSTALLATION
2.4.1
3-2-2
Orig
Remove the engine/compressor assembly from the frame as follows:
Install the engine/compressor assembly to the frame as follows:
a.
Attach the chain and hoist to the front engine lift ring and the two
compressor lifting eyes.
b.
Take the slack out of chain. Check the hoist connections.
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Chapter 3
Section 2
2.5
c.
Carefully lift the engine/compressor assembly over the frame and lower it
into position for mounting.
d.
Install the mounting bolts and secure the engine/compressor assembly to the
frame.
INSTALLATION AND RECONNECTION OF OTHER EQUIPMENT
2.5.1
Install and connect other equipment and/or hoses and wires as follows:
a.
Lift the enclosure and position it above the engine/compressor assembly.
b.
Carefully lower the enclosure into position on the trailer frame.
c.
Using the bolts removed in step (k) of paragraph 2.2.2, secure the enclosure
to the frame.
d.
Install the air pressure sensing lines on the discharge manifold.
e.
Install the air discharge flange and piping.
f.
Install the piping between the unloader valve and the silencer.
g.
Install the discharge manifold coupling and tie-rods. Refer to MI 11020A for
compressor discharge coupling tie rod torque specifications.
h.
Install the exhaust pipe between the engine’s exhaust manifold and its
muffler.
i.
Reconnect the electrical wiring tagged in step (f) of paragraph 2.2.2.
j.
Reconnect all fuel lines, drain lines, oil cooler hoses, drain hoses, fuel, and
any other disconnected lines or hoses removed and tagged in step (e) of
paragraph 2.2.2.
k.
Reconnect all pressure lines and electrical wires to the Gauge and Meter
panel that were tagged and disconnected in step (d) of paragraph 2.2.2.
l.
Install all engine-to-radiator hoses and clamps.
m.
Fill the cooling system with a proper coolant mixture, as specified in the
Detroit Diesel Series 60 Service Manual, (under separate cover).
Install the battery’s ungrounded cable before the ground cable to
prevent burns and electrical sparks. Connect the ground cable to
the battery terminal before reconnecting it to its grounding point.
n.
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4940
Reconnect the battery cables. Connect the ungrounded cable first. Tighten all
connections.
3-2-3
Rev 1
Chapter 3
Section 2
2.6
REMOVAL OF AIR PRESSURE REGULATOR(S)
The battery’s ground cable must be removed before the ungrounded
cable to prevent burns and electrical sparks. The ground cable must
be removed from its ground point before removing the ground cable
from the battery.
2.6.1
2.7
a.
Tag and disconnect battery cables. Disconnect the battery ground cable first.
b.
Disconnect air signal hose (3) from quick connect fitting (4) at base of
regulator body.
c.
Disconnect control air hose (9) from quick connect fitting (8) at base of
solenoid valve (10).
d.
Remove both solenoid base mounting screws (11).
e.
Disconnect both solenoid wires from connectors on terminal strip (12). Note
where wires terminate.
f.
Remove solenoid valve (10), solenoid base mounting plate (6), adapter
fitting (5), and regulator as one assembly from the air logic control box.
g.
Remove adapter fitting (5) from base of regulator.
INSTALLATION OF AIR PRESSURE REGULATOR
2.7.1
3-2-4
Rev 2
Refer to Figure 3.1. Remove either of the air pressure regulators as follows:
Refer to Figure 3.1. Install the air pressure regulator as follows:
a.
Install adapter fitting (5) into base of regulator body. Install adapter fitting
(5) into base of solenoid valve (10) if required.
b.
Install solenoid valve (10), solenoid base mounting plate (6), and adapter
fitting (5) as one assembly into the air logic control box with both solenoid
base mounting screws (11).
c.
Connect control air hose (9) into quick connect fitting (8) at base of solenoid
valve (10).
d.
Connect air signal hose (3) to quick connect fitting (4) at base of regulator.
e.
Connect both solenoid valve wires into terminal strip (12). Be sure to
reinstall both wires into the same location from which they were removed
(see Paragraph 2.6).
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Chapter 3
Section 2
Figure 3.1
2.8
Regulator/Solenoid Assembly Typical
Jet Start/Air Packs (Sheet 1 of 2)
REMOVAL AND REPLACEMENT OF AIR SOLENOID VALVES
2.8.1
Removal of Air Solenoid Valves. Remove air solenoid valves as follows:
The battery’s ground cable must be removed before the ungrounded
cable to prevent burns and electrical sparks. The ground cable must
be removed from its ground point before removing the ground cable
from the battery.
CD295
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3-2-5
Rev 2
Chapter 3
Section 2
a.
Tag and disconnect battery cables. Disconnect the battery ground cable first.
b.
Disconnect control air hose (9) from quick connect fitting (8) at base of
solenoid valve (10).
c.
Remove both solenoid base mounting screws (11).
d.
Disconnect both solenoid wires from connectors on terminal strip (12). Note
where wires terminate.
e.
Disconnect air signal hose (3) from quick connect fitting (4) at base of
regulator body.
f.
Remove solenoid valve (10), solenoid base mounting plate (6), adapter
fitting (5), adapter fitting (8), and regulator body as one assembly from the
air logic control box.
g.
Remove adapter fitting (5) from base of solenoid valve (10).
h.
Remove both solenoid mounting screws (7).
Installation of Air Solenoid Valves. Install air solenoid valves as follows:
2.8.2
3-2-6
Rev 2
a.
Install adapter fitting (5) into base of regulator body.
b.
Mount solenoid body (10) to adapter fittings (5) and (8).
c.
Mount solenoid base mounting plate (6) to solenoid with both solenoid
mounting screws (7).
d.
Install solenoid valve (10), solenoid base mounting plate (6), and adapter
fittings (5) and (8) as one assembly into the air logic control box with both
solenoid base mounting screws (11).
e.
Connect control air hose (9) into quick connect fitting (8) at base of solenoid
valve (10).
f.
Connect air signal hose (3) to quick connect fitting (4) at base of regulator.
g.
Connect both solenoid valve wires into terminal strip (12). Be sure to
reinstall both wires into the same location from which they were removed
(see Paragraph 2.8.1, Removal of Air Solenoid Valves).
h.
Connect battery cables onto battery. Connect the ungrounded battery cable
first.
i.
Test operation of Air Solenoid valves by operating unit. Operating instructions are contained in Chapter 1, Section 2.
CD295
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Chapter 3
Section 2
Figure 3.1
CD295
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Regulator/Solenoid Assembly Typical
Jet Start/Air Packs (Sheet 2 of 2)
3-2-7
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Chapter 3
Section 2
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Chapter 4
TOC
Chapter 4
Illustrated Parts Breakdown
TABLE OF CONTENTS
Section/
Description
Paragraph
Page
1
1.1
1.2
1.3
1.4
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Using the Illustrated Parts List (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
How to Locate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
How to Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
2
2.1
Manufacturer’s Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1
3
3.1
Alphanumeric Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1
4
Group Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1
CD295
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Group 1
TMD-150/180/250 Air Start Unit . . . . . . . . . . . . . . . . . 4-4-1-1
Group 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-2-1
Group 3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-3-1
Group 4
Engine Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-4-1
Group 5
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . 4-4-5-1
Group 6
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 4-4-6-1
Group 7
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 4-4-7-1
Group 8
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-8-1
Group 9
Air Compressor Cooling and Lubrication . . . . . . . . . . . 4-4-9-1
Group 10
Compressor Air Distribution and Regulation System . .4-4-10-1
4-TOC-i
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Chapter 4
TOC
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4-TOC-ii
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Chapter 4
Section 1
Chapter 4, Section 1
Parts List
1.1
INTRODUCTION
1.1.1
Your Air Start Unit was manufactured by TUG Technologies Corporation. The
finest quality materials, selected through years of research and experience, have
been combined with precision workmanship and careful inspection to deliver a
product that will provide you with many years of dependable, trouble-free
operation.
1.1.2
This parts breakdown has been prepared to help you locate parts required to
maintain your Air Start Unit. An alphanumeric index is included in Section 3 of
this chapter.
For your own protection, do not use substitute parts without the
approval of TUG Technologies Corporation.
1.2
PARTS LIST DETAIL
1.2.1
The Parts List illustrates, lists, and identifies components, assemblies, subassemblies, sub-subassemblies, and detailed parts required for maintenance of the
equipment. The Parts Lists, cross-indexed for reference and illustrated, are
presented in tabular form. The columns, reading from left to right, are headed:
Figure & Index Number, Part Number, Manufacturer's Code, Description,
Quantity, and Usable On Code. (Refer to Table 4.1)
Ta ble 4 . 1
Fig &
Ind #
Ex a m p l e , Pa r ts L i s t
Part Number
MFR
Code
5.1
Description
Qty
Usable
On Code
B
CO O L I N G S Y S T E M
-1
51 2 2 4 8 2
71 5 8 2
Pulley Assembly
1
-2
311D
19 0 9 0
Pulley
1
-3
NO NUMBER
COML
N u t , H e x L o c k , 5 / 1 6 - 2 4 , St e e l
Ca dmi u m P lat ed
AR
-4
89 2 11 0 5
72 5 8 2
Wa t e r P u m p
REF
CD295
4-1-1
Rev 6
Chapter 4
Section 1
1.2.2
1.2.3
a.
The first item in the Figure and Index Number column is the figure number
of the illustration. Each subsequent “dash number” corresponds to the illustration's index number.
b.
Identical parts occurring in the same illustration are illustrated and indexed
once except when identical parts need to be identified for clarity. Identical
parts occurring in other illustrations are identified and listed for that illustration.
Part Number Column.
a.
Part numbers used in this column are selected according to the following
order of preference: Original Manufacturer, Commercial Manufacturer,
Prime Design Manufacturer.
b.
“No Number” appearing in the Part Number column indicates that the part or
assembly is of common usage and usually can be purchased locally.
1.2.4
Manufacturer's Code Column. The Manufacturer’s Code column lists the fivenumber code assigned to the manufacturers in the Federal Supply Codes for
Manufacturers Handbook. This number represents the name and address of the
vendor. Refer to Section 2 for the list of code numbers referenced to each
manufacturer's name and address. If “COML” appears as a Manufacturer's Code,
the item is of common usage and usually can be purchased locally.
1.2.5
Description Column.
1.2.6
4-1-2
Orig
Figure And Index Number Column.
a.
The Description column gives the parts’ names as assigned by the manufacturer plus any additional modifiers necessary to ensure they can be
identified. Items that are part of an assembly are preceded by one dot. Each
dot associates the part to the previously-listed item without a dot. Items
which are part of a subassembly are preceded by two dots, which associate
the part to the previously-listed item with one dot. Attaching parts are listed
beneath the item they attach. They are captioned, ATTACHING PARTS, and
are followed by the separation symbol “*****” to distinguish them from
subsequent listings of assemblies or detail parts.
b.
Items that are available commercially also are identified in this column; e.g.,
“Nut, Hex, Lock, 5/16-24, Steel, Cadmium Plated”.
Quantity Column. The Quantity column indicates the number of units per
component, assembly, subassembly, and/or sub-subassemblies. The quantity
required for one item is given except when identical parts are used. When items
are listed for reference purposes, “REF” is used in the quantity column. This
indicates that the item appears elsewhere in the manual where the units per
assembly are given. “AR” in the quantity column stands for “As Required”.
CD295
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Chapter 4
Section 1
1.2.7
1.3
HOW TO LOCATE PARTS
1.3.1
1.4
Usable On Code. Part variations are indicated by a letter in this column. Applicability of the letter codes given in the USABLE ON CODE column are given in the
manual's introduction. When this column is left blank, the parts listed apply to all
units.
Parts may be readily located in this IPB by referring to the Group Index, Chapter
4, Section 4. Determine the group number in which the part appears and refer to
the group in the Parts List. Illustrations are included to aid you in identifying
parts.
HOW TO ORDER PARTS
1.4.1
Place parts orders with TUG Technologies Corporation, 815 Allgood Rd. Marietta
Ga. 30062. TUG maintains a large stock of repair parts to assure prompt delivery
of needed parts.
1.4.2
When ordering parts, list the quantity, part number, manufacturer's code, and
complete description of the needed part(s) to ensure fast delivery.
1.4.3
In case of difficulty, wire or write TUG Technologies Corporation, 815 Allgood
Rd. Marietta Ga. 30062. Be sure to list the equipment model number, rating,
specific nature of the problem, and the suspected area of malfunction.
For emergency assistance, call:
For Airline Parts: 800-989-8499 (Georgia Residents 770-422-7230)
For Airline Service: 770-422-7230 (ask for Warranty Dept.)
CD295
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Chapter 4
Section 1
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4-1-4
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Chapter 4
Section 2
Chapter 4, Section 2
Manufacturers Identification
2.1
INTRODUCTION
2.1.1
The Manufacturers Identification table (Table 4.2) lists the code and contact
information for manufacturers referenced in the parts list.
Ta ble 4 . 2
CODE
81381
M a nu f a c t u re rs I d e n t i f i c a t i o n
NAME AND ADDRESS
TUG Technologies Corporation
815 Allgood Rd.
Marietta Ga. 30062
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Chapter 4
Section 2
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4-2-2
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Chapter 4
Section 3
Chapter 4, Section 3
Alphanumeric Index
3.1
INTRODUCTION
3.1.1
The Alphanumeric Index (Table 4.3) consists of four columns: FIGURE &
INDEX NO., PART NUMBER, QUANTITY, AND TUG PART NO.
3.1.2
The Figure & Index Number matches each part number with the exact figure and
callout number that depicts that part. The number before the dash indicates the
figure number, and the number after the dash is the callout number on the figure.
For example, if number 2.1-7 is listed, refer to Figure 2.1and locate item 7.
3.1.3
The Part Number column lists the part number assigned or used by TUG Technologies Corporation for stocking or ordering purposes.
3.1.4
The Quantity column lists the amount of parts used in that particular listing.
“REF” (reference) indicates the quantity of that part has been listed in another
Figure and Index column.
3.1.5
The TUG Part Number column is provided for the customer’s use only and,
therefore, has been left blank.
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex
Fig & Index No.
Part Number
Quantity
6.1-6
A4 6
Set/3
8.4-15
BL-50
4
8.5-12
BL-50
4
8.2-8
BN D N 1 0 0 0
8.2-9
BN L 5
4
8.4-14
CGB193
2
8.5-11
CGB193
2
10.1-10
CT450
2
6.3-6
CT450
4
8.4-26
F H AC - 1
2
9.1-8
GG106-NP-12-08
1
9.1-3
GG106-NP-12-16
2
4.1-1
G112401
1
8.1-3
G2OUB4-FTG-7342
1
CD295
TUG Part Number
1-Cut
4-3-1
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-2
Rev 6
Part Number
Quantity
10.1-2
H000349
1
8.1-20
IN 4 0 0 6
1
8.2-23
IN 4 0 0 6
17
8.3-14
LE000005
1
8.3-16
LE000018
1
8.1-12
LE000062
10
8.1-14
LE000063
8
8.1-13
LE000064
10
8.1-15
LE000065
2
8.2-10
LE000106
1
8.1-16
LE000108
2
8.2-22
LE000131
24
8.3-4
LE000151
3
8.3-5
LE000152
2
8.3-39
LE000157
REF
8.2-28
LE000191
2
8.2-29
LE000192
2
8.1-17
LE000249
1
8.2-14
LE000252
1
8.1-22
LE000307
1
8.2-21
LE000318
10
8.4-9
LE000318
1
8.1-2
LE000321
3
6.2-7
MB9425T75S283F
4
8.1-18
MS24523-26
0
8.1-21
MS35058-22
1
8.1-9
MS35058-26
1
8.2-24
MS37TB24-VF-10
1
8.2-26
MS37TB24-VF-40
1
8.2-18
MS37TB31-10
1
8.2-20
MS37TB31-40
1
4.1-5
P004079
2
4.1-7
P1 0 5 5 3 5
1
4.1-2
P105695
1
7.1-2
P2 7 0 5 4 3
1
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
3.3-7
P828480
2
8.2-5
RY 4 S - U L D C 2 4 V
17
10.1-7
SA000008
1
1.1-1
SA 0 0 0 0 0 9
1
1.1-2
SA000010
2
1.6-1
SA 0 0 0 0 1 0
2
9.1-9
SA000018
1
9.1-10
SA000019
1
9.1-11
SA000020
1
9.1-12
SA000021
1
3.1-12
SA000022
1
3.2-12
SA000022
1
3.3-14
SA000022
1
3.1-5
SA 0 0 0 0 2 3
1
3.2-5
SA000023
1
3.2-17
SA000025
1
3.2-21
SA000026
1
10.1-27
SA000034
1
3.1-1
SA000037
1
3.2-1
SA 0 0 0 0 3 7
1
2.1-1
SA000042
REF
2.1-3
SA 0 0 0 0 4 9
1
2.1-1
SA000051
REF
2.1-1
SA 0 0 0 0 5 2
REF
3.3-8
SA000101
1
3.3-11
SA000102
1
10.3-3
SD000005
1
10.1-20
SD000006
1
2.1-2
SD000024
1
2.1-2
SD 0 0 0 0 2 4
1
2.1-6
SD000033
1
6.2-2
SD 0 0 0 0 5 5
1
10.1-9
SD000073
1
10.1-12
SD000074
1
6.1-3
SD000079
1
CD295
TUG Part Number
4-3-3
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-4
Rev 6
Part Number
Quantity
10.1-13
SD 0 0 0 0 8 3
3
10.1-14
SD000084
3
6.3-4
SD 0 0 0 0 8 6
1
6.3-3
SD000089
2
10.1-11
SD 0 0 0 1 0 5
1
6.3-7
SD000105
1
9.1-1
SD 0 0 0 1 0 8
1
10.1-22
SD000109
1
1.6-2
SD 0 0 0 1 4 5
1
1.6-5
SD000146
2
1.6-6
SD 0 0 0 1 4 8
1
1.6-7
SD000149
1
9.1-2
SD 0 0 0 1 7 7
1
6.1-5
SD000196
1
1.7-3
SD 0 0 0 1 9 9
1
1.7-1
SD000200
1
1.7-2
SD 0 0 0 2 0 1
1
10.1-20
SD000214
1
10.1-5
SD000216
2
8.4-19
SD000238
1
6.2-1
SD 0 0 0 2 8 4
1
8.2-16
SD000285
1
1.6-12
SD000345
1
1.6-13
SD000346
1
7.1-6
SD 0 0 0 3 6 9
1
7.1-4
SD000370
1
8.2-3
SD 0 0 0 3 9 0
1
8.2-4
SD000391
1
8.2-17
SD000392
1
3.3-5
SD000417
2
10.1-38
SD 0 0 0 4 2 2
1
10.1-40
SD000519
REF
10.1-41
SD 0 0 0 5 2 0
2
6.3-5
SD000531
1
8.4-23
SE000001
1
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
8.5-19
SE000001
1
8.5-17
SE000002
1
8.5-18
SE000003
1
8.4-24
SE000004
1
8.5-20
SE000004
1
8.2-31
SE000006
1
8.3-32
SE000007
1
8.4-11
SE000008
1
8.5-8
SE000008
1
8.4-12
SE000009
1
8.5-9
SE000009
1
8.4-13
SE000010
1
8.5-10
SE000010
1
8.1-1
SE 0 0 0 0 1 3
1
8.5-16
SE000015
1
8.5-6
SE 0 0 0 0 1 7
1
8.5-2
SE000023
1
8.3-6
SE 0 0 0 0 2 7
1
8.2-11
SE000031
1
8.2-12
SE000032
1
8.2-13
SE000033
1
8.3-12
SE000034
REF
8.4-10
SE000035
1
8.5-7
SE 0 0 0 0 3 5
1
8.5-3
SE000036
1
8.1
SE 0 0 0 0 3 8
1
8.2-30
SE000039
1
8.5-1
SE 0 0 0 0 3 9
1
8.2
SE000040
1
8.2-15
SE000041
1
8.2-27
SE000042
1
8.3-1
SE 0 0 0 0 4 3
1
8.3-3
SE000044
REF
8.4-3
SE 0 0 0 0 4 4
REF
8.3-13
SE000045
1
CD295
TUG Part Number
4-3-5
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-6
Rev 6
Part Number
Quantity
8.3-19
SE000046
1
8.3-20
SE000047
1
8.3-42
SE000048
1
8.3-43
SE000050
1
8.3-40
SE000052
1
8.3-41
SE000052
1
3.3-10
SE000073
1
10.1-8
SG000008
1
8.1-19
SL000003
1
8.3-8
S M - 2 C - 1 2 F - AU
1
8.3-22
SM-2C-34F/BT
1
1.6-10
SPD-1007
2
1.6-11
SPD-1008
2
1.6-9
SPD-3100200
2
2.1-2
SP 0 0 0 0 0 6
1
2.1-2
SP000007
1
2.1-2
SP 0 0 0 0 0 8
1
10.1-1
SP000011
1
7.1-1
SP 0 0 0 0 1 4
1
10.3-1
SP000015
1
4.1-4
SP 0 0 0 0 2 1
1
4.1-6
SP000022
1
9.1-14
SP000026
1
6.1-1
SP000031
1
6.3-2
SP 0 0 0 0 3 7
4
10.1-6
SW000002
1
3.1-14
SW000006
1
3.2-14
SW000006
1
1.1-10
SW000008
1
1.1-9
SW000012
1
6.1-4
SW 0 0 0 0 1 4
1
6.1-2
SW000017
1
10.1-24
SW 0 0 0 0 1 9
1
10.1-4
SW000021
1
6.3-1
SW 0 0 0 0 2 3
1
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
1.1-3
SW000035
1
10.1-25
SW000037
1
6.1-7
SW000058
1
1.1-5
SW 0 0 0 0 7 8
1
3.3-6
SW000082
2
8.6-8
SW 0 0 0 0 8 7
1
10.1-37
SW000115
1
8.2-6
SY 4 S - 0 5
17
8.2-7
SY4S-51F1
17
8.3-11
T T- 2 A - 0 1 0 0 - 1 7 6 R
1
10.1-3
X005832
2
7.1-3
X0 0 5 8 3 3
1
1.2-2
01-10027
2
8.1-23
02011-10
5
1.4-11
020-20706
1
1.3-24
02-02370
1
1.4-4
02-02370
1
1.2-18
02-03207
2
1.3-4
02-03207
2
1.2-17
02-03916
2
1.3-3
02-03916
2
1.4-13
02-12103
6
1.1-8
02-20143
1
1.4-3
02-20143
1
1.3-12
02-20212
1
1.3-2
02-20322
2
1.3-11
02-20409
1
1.2-7
02-20704
2
1.2-8
02-20705
2
1.4-7
02-20707
1
1.4-9
02-20731
2
1.4-8
02-20732
2
1.2-11
02-20735
2
1.1-6
02-20737
4
1.4-14
02-20737
4
CD295
TUG Part Number
4-3-7
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-8
Rev 6
Part Number
Quantity
1.4-10
03-18451
1
1.3-1
03-30241
1
1.2-1
03-30548
1
1.1-7
04-40379
1
1.4-1
04-40379
1
1.1-4
04-40380
1
1.4-2
04-40380
1
1.2-26
06-11814
2
1.3-9
06-12016
2
1.2-28
06-12103
10
1.3-20
06-12103
6
1.3-21
06-12104
6
1.4-12
06-12104
6
1.3-26
06-13144
10
1.2-29
06-60136
4
1.3-22
06-60295
3
1.3-13
06-60403
1
1.3-10
06-60440
10
1.3-18
06-60479
1
1.3-19
06-60538
6
1.2-23
06-60591
2
1.2-27
06-60591
10
1.2-10
06-61435
8
1.2-4
06-61819
2
1.2-9
06-61835
4
1.4-15
06-61849
2
1.2-16
06-61900
3
1.2-3
06-61901
4
8.4-20
10478980
1
1.7-4
1078-3"
2
8.3-2
1110
4
8.6-2
1110
4
8.3-32
12065287
REF
8.3-32
12103881
REF
10.1-29
121901382
2.5
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
10.2-14
12313910
1
6.2-3
12892909
6 .5
6.2-6
12901644
2
8.3-34
12911262
1
6.3-8
12912045
1
8.6-4
12922244
1
8.1-8
12930787
1
10.1-15
12950251
1
2.1-2
12950282
2
2.1-2
12950282
2
2.1-2
12950282
2
2.1-2
12950284
1
2.1-2
12950284
1
1.6-3
12950501
1
1.6-8
12950502
1
10.1-18
12950531
1
8.2-32
12950802
1
8.3-33
12950803
REF
10.1-23
12970123
1
8.1-4
12980039
1
2.1-5
12980044
2
1.2-22
130355100
2
1.3-17
130355100
1
1.3-8
130355100
2
1.2-21
130360200
2
1.3-16
130360200
1
1.3-7
130360200
2
1.2-20
130395200
2
1.3-6
130395200
2
1.2-19
130400100
2
1.3-5
130400100
2
1.3-15
130405200
1
1.3-14
130580500
1
10.1-28
169X6X6
1
8.4-4
19010182
1
CD295
TUG Part Number
4-3-9
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-10
Rev 6
Part Number
Quantity
8.6-3
2MJ7
4
3.3-15
2021-32-32S
2
3.3-2
2025-6-8S
1
3.1-9
208007-4-2S
1
3.2-9
208007-4-4S
1
3.1-10
2081-4-2S
1
3.2-10
2081-4-2S
1
3.3-4
2083-12-6S
1
3.1-4
2083-12-8S
1
3.2-4
2083-12-8S
1
3.1-8
2089-4-2S
1
3.2-8
2089-4-2S
1
3.2-19
2092-8-8S
1
9.1-5
2216-12-16S
1
6.2-4
2256-4RL
3.7
3.2-3
232B-4P
1
3.1-3
232B-4PP
1
7.1-5
23506159
1
6.2-9
23515397
1
8.4-1
23515397
1
8.3-21
23518254
1
3.1-7
23518482
1
3.2-7
23518482
1
8.3-23
23520025
1
8.4-22
23520025
1
8.4-8
24063-09
1
8.4-7
240-903
2
8.4-17
257005
1
8.5-14
257005
1
8.4-16
257010
1
8.5-13
257010
1
8.4-18
257015
2
8.5-15
257015
2
1.6-4
279L
1
8.1-25
3SB02-K4R11
1
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
8.1-10
301-904
1
8.1-5
310-910
2
1.2-15
3202224100
8
1.3-25
320700140
1
1.2-24
321415140
2
1.3-23
321415140
3
1.4-5
321415140
1
1.2-5
321510110
8
1.2-13
321800090
8
1.2-30
322400100
4
8.4-5
323-093
1
3.3-1
3232290
1
1.2-6
324000110
8
1.2-25
324612100
2
1.4-6
324612100
1
8.1-11
332-902
1
8.1-6
350-902
1
8.1-7
350-906
2
8.3-9
360-003
1
8.4-6
360-086
2
8.3-10
360-094
1
8.2-25
37TB-24
2
8.2-19
37TB-31
2
1.2-12
390908028
2
1.5-5
390908028
1
1.5-1
41-308664
2
1.5-3
41-308665
1
1.5-4
41-308743
1
1.5-2
41-415200
2
8.1-24
44204LN
1
6.2-11
4738-4-4B
1
10.3-2
484P
1
3.2-15
5110760
1
2.1-4
512-3-N-S
2
2.1-2
516-5-N-S
2
CD295
TUG Part Number
4-3-11
Rev 6
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
4-3-12
Rev 6
Part Number
Quantity
10.2-2
55AA532
1
10.2-5
55AA533
1
10.1-30
56AA546
1
10.1-31
56AB252
1
10.2-11
56AB252
1
10.1-21
5 7 AC 5 1 8
1
10.2
5 7 AC 8 8 4
REF
10.2-4
58AA050
1
10.2-6
58AA051
1
10.2-1
58AB052
1
8.6-1
6S1375-1
1
10.1-42
69726
4
8.6-6
70018
2
8.2-2
70120C
2
8.2-1
7022OF
1
10.2-8
71068
1
10.2-13
73807
1
10.2-12
73821
1
10.2-9
74626
1
3.3-13
76563
1
9.1-4
76941
4
3.1-11
77006
1
3.2-11
77006
1
3.3-12
77006
3
3.2-22
77735
1
3.1-13
77738
1
3.2-13
77738
1
6.2-8
77741
1
6.2-12
77746
1
10.1-16
78175
1
9.1-6
78175
1
4.1-3
78603
4
3.2-16
78886
2
10.1-26
78890
1
3.2-20
78890
1
TUG Part Number
CD295
Chapter 4
Section 3
Ta ble 4 . 3
Al p h a nu m e r i c I n d ex ( C o n t . )
Fig & Index No.
Part Number
Quantity
3.1-6
78894
1
3.2-6
78894
1
3.2-18
78896
1
3.1-2
78898
1
3.2-2
78898
1
9.1-7
78904
3
6.2-5
79382
2
8.3-35
837-N1
1
3.3-3
87046
1
3.3-9
87903
4
10.1-39
88090
1
10.1-17
88110
1
6.2-10
8924187
1
10.3-4
93290
12
10.2-10
94859
1
10.1-19
97904
1
10.2-7
97905
1
CD295
TUG Part Number
4-3-13
Rev 6
Chapter 4
Section 3
This Page Intentionally Left Blank
4-3-14
Rev 6
CD295
Chapter 4
Section 4
Chapter 4, Section 4
Group Index
Index
Title
Group 1
Air Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1-1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TMD-150/180/250 Overall Assembly . . . . . . . . . . . . . . . . . . . 4-4-1-2
TMD-150/180/250 Overall Rear Axle Assembly . . . . . . . . . . . 4-4-1-4
Fifth Wheel Hub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1-6
Overall Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1-8
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4-1-10
Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4-4-12
Hose Basket Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . .4-4-1-14
Group 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-2-1
2.1
Engine Assembly, TR/TMD-150/180/250 . . . . . . . . . . . . . . . . 4-4-1-2
Group 3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-3-1
3.1
3.2
Standard Fuel Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-3-2
Standard Fuel Kit Assembly with Manual Prime Pump Option 4-4-3-4
Group 4
Engine Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-4-1
4.1
Engine Air Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-4-2
Group 5
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . 4-4-5-1
Group 6
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . 4-4-6-1
6.1
6.2
6.3
Fan Drive Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-6-2
Jacket Water Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-4-6-4
Charge Air Cooler Parts Assembly . . . . . . . . . . . . . . . . . . . . 4-4-6-6
Group 7
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 4-4-7-1
7.1
Engine Exhaust Parts Assembly . . . . . . . . . . . . . . . . . . . . . . 4-4-7-2
CD295
4327
Page
4-4-1
Orig
Chapter 4
Section 4
GROUP INDEX (CONT.)
Index
Title
Page
Group 8
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-8-1
8.1
8.2
8.3
8.4
8.5
8.6
Control and Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-8-2
Engine Electrical Components . . . . . . . . . . . . . . . . . . . . . . . 4-4-8-6
Compressor, Fuel Tank, and Skid Electrical Components . . .4-4-8-12
Engine Electrical Components . . . . . . . . . . . . . . . . . . . . . . .4-4-8-24
Engine ECM and Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . .4-4-8-32
Battery Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4-8-34
Group 9
Air Compressor Cooling and Lubrication . . . . . . . . . . 4-4-9-1
9.1
Lube Oil GHH Compressors . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-9-2
Group 10 Compressor Air Distribution and
Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-10-1
10.1
10.2
10.3
4-4-2
Orig
Discharge/Unloader Parts Assembly . . . . . . . . . . . . . . . . . .4-4-10-2
Unloader Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .4-4-10-6
Compressor Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . .4-4-10-8
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 1
TMD-150/180/250 Air Start Unit
CD295
4327
4-4-1-1
Orig
Chapter 4
Section 4
Figure 1.1 TMD-150/180/250 Overall Assembly
4-4-1-2
Orig
CD295
4327
Chapter 4
Section 4
Table 1.1 TMD-150/180/250 Overall Assembly
Fig &
Ind #
Part Number
MFR
Code
1.1
Description
Qty
TMD-150/180/250 OVERALL
ASSEMBLY
-1
SA000009
81381
. Enclosure Assembly
1
-2
SA000010
81381
. Door Assembly
2
-3
SW000035
81381
. Bumper, Rear
1
-4
04-40380
81381
. Rear Axle Assembly
1
-5
SW000078
81381
. Hose Basket Assembly
1
-6
02-20737
81381
. Tire/Wheel Assembly
4
-7
04-40379
81381
. Front 5th Wheel Assembly
1
-8
02-20143
81381
. Towbar Assembly
1
-9
SW000012
81381
. Front Gooseneck Assembly
1
-10
SW000008
81381
. Main Frame Assembly
1
CD295
4327
Usable
On Code
4-4-1-3
Orig
Figure 1.2 TMD-150/180/250 Overall Rear Axle Assembly
Chapter 4
Section 4
4-4-1-4
Orig
CD295
4327
Chapter 4
Section 4
Table 1.2 TMD-150/180/250 Overall Rear Axle Assembly
Fig &
Ind #
Part Number
MFR
Code
1.2
Description
Qty
TMD-150/180/250 OVERALL REAR
AXLE ASSEMBLY
-1
03-30548
81381
. Rear Axle Weldment
1
-2
01-10027
81381
. Leaf Spring, 5 Leaf
2
-3
06-61901
81381
. U-Bolt, 5/8-18
4
-4
06-61819
81381
. Tie Plate
2
-5
321510110
81381
. Nut, 5/8-18 UNF Hex
8
-6
324000110
81381
. 5/8 Lock Washer
8
-7
02-20704
81381
. Front Shackle Weldment
2
-8
02-20705
81381
. Rear Shackle Weldment
2
-9
06-61835
81381
. Dust Shield for 9" Brake
4
-10
06-61435
81381
. Dust Shield Spacer
8
-11
02-20735
81381
. Brake Lever Weldment, w/ 3/4 offset
2
-12
390908028
81381
. 9 x 2 Mechanical Parking Brake
2
-13
321800090
81381
. 1/2-13 Nut
8
-14
NOT USED
-15
3202224100
81381
. Bolt, 1/2-13 x 2.00
8
-16
06-61900
81381
. 9 x 2 Brake Drum, 3.13 Long
3
-17
02-03916
81381
. Hub, #623 5 on 5.5 bolt pattern
2
-18
02-03207
81381
. Grease Seal
2
-19
130400100
81381
. Inner Cone, #24780
2
-20
130395200
81381
. Inner Cup, #24720
2
-21
130360200
81381
. Outer Cup, #15245
2
-22
130355100
81381
. Outer Cone, #15123
2
-23
06-60591
81381
. 1" Tongued Washer
2
-24
321415140
81381
. Nut, Slotted Hex, 1-14
2
-25
324612100
81381
. Cotter Pin, 1/8 x 1.50
2
-26
06-11814
81381
. Grease Cap, #623
2
-27
06-60591
81381
. Wheel Stud, 1/2-20
10
-28
06-12103
81381
. Wheel Nut, 1/2-20
10
-29
06-60136
81381
. Shackle Bolt, 9/16-18
4
-30
322400100
81381
. Nut, 9/16-18 Locking Jam
4
CD295
4327
Usable
On Code
4-4-1-5
Orig
Chapter 4
Section 4
Figure 1.3 Fifth Wheel Hub Assemblies
4-4-1-6
Orig
CD295
4327
Chapter 4
Section 4
Table 1.3 Fifth Wheel Hub Assemblies
Fig &
Ind #
Part Number
MFR
Code
1.3
Description
Qty
FIFTH WHEEL HUB ASSEMBLIES
-1
03-30241
81381
. Front Axle Weldment, T.I. STND. 5th
Wheel
1
-2
02-20322
81381
. Hub Assembly, #623
2
-3
02-03916
81381
. Hub, #623 Cupped and Studded
2
-4
02-03207
81381
. Grease Seal, #623
2
-5
130400100
81381
. Inner Cone, #24780
2
-6
130395200
81381
. Inner Cup, #24720
2
-7
130360200
81381
. Outer Cup, #15245
2
-8
130355100
81381
. Outer Cone, #15123
2
-9
06-12016
81381
. Grease Cap, #623
2
-10
06-60440
81381
. Wheel Stud, 1/2-20 UNF
10
-11
02-20409
81381
. Hub Assembly, 655/#42 Idler
1
-12
02-20212
81381
. Hub, Cupped and Studded, #655 Idler
1
-13
06-60403
81381
. Grease Seal, #22550
1
-14
130580500
81381
. Inner Cone, #25580
1
-15
130405200
81381
. Inner Cup, #25520
1
-16
130360200
81381
. Outer Cup, #15245
1
-17
130355100
81381
. Outer Cone, #15123
1
-18
06-60479
81381
. Grease Cap, #1520
1
-19
06-60538
81381
. Wheel Stud, 1/2-20 UNF
6
-20
06-12103
81381
. Nut, 1/2-20 Hex Nut
6
-21
06-12104
81381
. Washer, 1/2 Lock
6
-22
06-60295
81381
. Washer, 1" Tongue Spindle
3
-23
321415140
81381
. Nut, 1-14 UNF Slotted Hex Spindle
3
-24
02-02370
81381
. Queen Bolt, 1-14 x 8.75
1
-25
320700140
81381
. Nut, 1-14 Hex Jam
1
-26
06-13144
81381
. Nut, 1/2-20 Tapered Hex Wheel
10
CD295
4327
Usable
On Code
4-4-1-7
Orig
Chapter 4
Section 4
Figure 1.4 Overall Axle Assembly
4-4-1-8
Orig
CD295
4327
Chapter 4
Section 4
Table 1.4 Overall Axle Assembly
Fig &
Ind #
Part Number
MFR
Code
1.4
Description
Qty
OVERALL AXLE ASSEMBLY
-1
04-40379
81381
. Front Axle Assembly
1
-2
04-40380
81381
. Rear Axle Assembly
1
-3
02-20143
81381
. Drawbar Assembly, 6 x 48
1
-4
02-02370
81381
. Towbar Pin Weldment
1
-5
321415140
81381
. Nut, 1-14 Slotted
1
-6
324612100
81381
. Cotter Pin, 1/8 x 150
1
-7
02-20707
81381
. Cross Shaft
1
-8
02-20732
81381
. Short Brake Rod Assembly, 13.00 LG.
2
-9
02-20731
81381
. Long Brake Rod, 90.5" LG.
2
-10
03-18451
81381
. Brake Lever, Orscheln
1
-11
020-20706
81381
. Trunnion Weldment
1
-12
06-12104
81381
. 1/2" Lock Washer
6
-13
02-12103
81381
. Wheel Nut, 1/2-20
6
-14
02-20737
81381
. Tire/Wheel Assembly
4
-15
06-61849
81381
. Shaft Locking Collar
2
CD295
4327
Usable
On Code
4-4-1-9
Orig
Chapter 4
Section 4
Figure 1.5 Brake Assembly
4-4-1-10
Orig
CD295
4327
Chapter 4
Section 4
Table 1.5 Brake Assembly
Fig &
Ind #
Part Number
MFR
Code
1.5
Description
Qty
BRAKE ASSEMBLY
-1
41-308664
81381
. Spring, Shoe Return
2
-2
41-415200
81381
. Shoe and Lining
2
-3
41-308665
81381
. Spring, Retaining
1
-4
41-308743
81381
. Support Plate
1
-5
390908028
81381
. Brake Assembly, 9 x 2
1
CD295
4327
Usable
On Code
4-4-1-11
Orig
Chapter 4
Section 4
Figure 1.6 Door Assembly
4-4-1-12
Orig
CD295
4327
Chapter 4
Section 4
Table 1.6 Door Assembly
Fig &
Ind #
Part Number
MFR
Code
1.6
Description
Qty
DOOR ASSEMBLY
-1
SA000010
81381
. Assembly, Door, Gull-Wing, w/ Hinge
2
-2
SD000145
81381
. Hinge, Gull-Wing Door
1
-3
12950501
81381
. Latch for D-Ring
1
-4
279L
81381
. D-Ring, S.S., for Latch, Locking
1
-5
SD000146
81381
. Insulation Panel, RS-LS
2
-6
SD000148
81381
. Insulation Panel, Top
1
-7
SD000149
81381
. Insulation Panel, Bottom
1
-8
12950502
81381
. Striker, for Door Latch
1
-9
SPD-3100200
81381
. Strut, Gas, 200 LBF, 10-inch stroke
2
-10
SPD-1007
81381
. Stud, Ball, 13mm
2
-11
SPD-1008
81381
. Clip, Safety, 13mm
2
-12
SD000345
81381
. Retaining Sheet, Top 2" Perf.
(NOT SHOWN)
1
-13
SD000346
81381
. Retaining Sheet, Bottom 2" Perf.
(NOT SHOWN)
1
CD295
5395
Usable
On Code
4-4-1-13
Rev 2
Chapter 4
Section 4
Figure 1.7 Hose Basket Parts Assembly
4-4-1-14
Orig
CD295
4327
Chapter 4
Section 4
Table 1.7 Hose Basket Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
1.7
Description
Qty
HOSE BASKET PARTS ASSEMBLY
-1
SD000200
81381
. Basket, Hose, 150-250
1
-2
SD000201
81381
. Door, Hose Basket, 150-250
1
-3
SD000199
81381
. Hinge, Hose Basket
1
-4
1078-3"
81381
. Assembly, Bolt/Striker (for Hose Basket)
2
CD295
4327
Usable
On Code
4-4-1-15
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-1-16
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 2
Engine
CD295
4327
4-4-2-1
Orig
Chapter 4
Section 4
Table 2.1 Engine Assembly, TR/TMD-150/180/250
Fig &
Ind #
Part Number
MFR
Code
2.1
Description
Qty
Usable
On Code
DETROIT DIESEL ENGINE ASSEMBLY
-1
SA000042
81381
Engine Assembly, TR/TMD-150
REF
-2
SP000006
81381
. Engine, Detroit, Series 60 DDEC IV
1
SD000024
81381
. . Isolator, Compressor Vibration RH
1
12950284
81381
. . Isolator, Compressor Vibration LH
1
12950282
81381
. . Washer, Snubbing
2
-1
SA000051
81381
Engine Assembly, TR/TMD-180
REF
-2
SP000007
81381
. Engine, Detroit, Series 60 DDEC IV
1
SD000024
81381
. . Isolator, Compressor Vibration RH
1
12950284
81381
. . Isolator, Compressor Vibration LH
1
12950282
81381
. . Washer, Snubbing
2
-1
SA000052
81381
Engine Assembly, TR/TMD-250
REF
-2
SP000008
81381
. Engine, Detroit, Series 60 DDEC IV
1
516-5-N-S
81381
. . Isolator, Compressor Vibration RH & LH
2
12950282
81381
. . Washer, Snubbing
2
--- USED ON TR/TMD-150/180/250
-3
SA000049
81381
. Mount, Assembly, Detroit/GHH
1
-4
512-3-N-S
81381
. Isolator, Engine Vibration
2
-5
12980044
81381
. Washer, Snubbing
2
-6
SD000033
81381
. Mount, Engine, DDC Series 60
1
4-4-2-2
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 3
Fuel System
CD295
4327
4-4-3-1
Orig
Figure 3.1 nnStandard Fuel Kit Assembly
Chapter 4
Section 4
4-4-3-2
Orig
CD295
4327
Chapter 4
Section 4
Table 3.1 Standard Fuel Kit Assembly
Fig &
Ind #
Part Number
MFR
Code
3.1
Description
Qty
STANDARD FUEL KIT ASSEMBLY
-1
SA000037
81381
. Assembly, Fuel Tank (Trailer Unit)
1
-2
78898
81381
. Adapter, Connector, Male, Aeroquip 20218-8S
1
-3
232B-4PP
81381
. Valve, Check, 1/2" NPT
1
-4
2083-12-8S
81381
. Adapter, Nipple, 3/4" MNPT x 1/2" MNPT
1
-5
SA000023
81381
. Assembly, Hose, Fuel Pick-Up, 150-250
W/ S60
1
-6
78894
81381
. Adapter, Connector, Male, Aeroquip 20216-8S
1
-7
23518482
81381
. Filter, Fuel, Secondary
1
-8
2089-4-2S
81381
. Elbow, Reducing 90
1
-9
208007-4-2S
81381
. Cross
1
-10
2081-4-2S
81381
. Bushing, Reducer
1
-11
77006
81381
. Adapter, Elbow 90 Degree, Aeroquip
2024-12-8S
1
-12
SA000022
81381
. Assembly, Hose, Fuel Return, 150-250 W
S60
1
-13
77738
81381
. Clamp, Support, Hose, Clamp ID=.938
1
-14
SW000006
81381
. Mount/Fuel Tank
1
CD295
4327
Usable
On Code
4-4-3-3
Orig
Figure 3.2 Standard Fuel Kit Assembly with
Manual Prime Pump Option
Chapter 4
Section 4
4-4-3-4
Orig
CD295
4327
Chapter 4
Section 4
Table 3.2 Standard Fuel with Manual Prime Pump Option
Fig &
Ind #
Part Number
MFR
Code
3.2
Description
Qty
STANDARD FUEL WITH MANUAL
PRIME PUMP OPTION
1
-1
SA000037
81381
Assembly, Fuel Tank (trailer unit)
1
-2
78898
81381
. Adapter, Connector, Male, Aeroquip 20218-8S
1
-3
232B-4P
81381
. Valve, Check, 1/2" NPT
1
-4
2083-12-8S
81381
. Adapter, Nipple, 3/4" MNPT x 1/2" MNPT
1
-5
SA000023
81381
. Assembly, Hose, Fuel Pick-Up, 150-250
w/ S60
1
-6
78894
81381
. Adapter, Connector, Male, Aeroquip 20216-8S
1
-7
23518482
81381
. Filter, Fuel, Secondary
1
-8
2089-4-2S
81381
. Elbow, Reducing 90, Aeroquip 2089-4-2S
1
-9
208007-4-4S
81381
. Cross, Aeroquip 208007-4-2S
1
-10
2081-4-2S
81381
. Bushing, Reducer Aeroquip 2084-4-2S
1
-11
77006
81381
. Adapter, Elbow 90°, Aeroquip 2024-12-8S
1
-12
SA000022
81381
. Assembly, Hose, Fuel Return, 150-250 w/
S60
1
-13
77738
81381
. Clamp, Support, Hose, Clamp ID=.938
1
-14
SW000006
81381
. Mount/Fuel Tank
1
-15
5110760
81381
. Pump, Hand Priming
1
-16
78886
81381
. Adapter, Connector, Male Aeroquip 20212-4S
2
-17
SA000025
81381
. Assembly, Hose, Check Valve to Prime
Pump
1
-18
78896
81381
. Adapter, Connector, Male, Aeroquip 20218-4S
1
-19
2092-8-8S
81381
. Tee, Pipe, Internal/External
1
-20
78890
81381
. Adapter, Connector, Male, Aeroquip 20214-4S
1
-21
SA000026
81381
. Assembly, Hose, Prime Pump to
Secondary Fuel Filter, S60
1
-22
77735
81381
. Clamp, Support, Hose, Clamp ID=.502
1
CD295
Usable
On Code
4-4-3-5
Rev 6
Chapter 4
Section 4
Figure 3.3 Twin Fuel Tank Installation (Replaces earlier single-tank installations)
4-4-3-6
Rev 2
CD295
5395
Chapter 4
Section 4
Table 3.3 Twin Fuel Tank Installation (Replaces earlier single-tank instllations)
Fig &
Ind #
Part Number
MFR
Code
3.3
Description
Qty
TWIN-TANK FUEL KIT ASSEMBLY
1
-1
3232290
81381
. Pipe Cap, 2 1/2” Threaded, 150#
1
-2
2025-6-8S
81381
. Adapter, Elbow, 1/2” Tube to 3/8”
1
-3
87046
81381
. Valve, Check, In-Line, 3/8” NPT
1
-4
2083-12-6S
81381
. Fitting, Aeroquip, Pipe-To-Pipe
1
-5
SD000417
81381
. Strap, Saddle, Fuel Tank
2
-6
SW000082
81381
. Tank, Fuel, Saddle, w/Fuel Sender
2
-7
P828480
81381
. Plug, Pipe, Flush, 1 1/2” Threaded
2
-8
SA000101
81381
. Hose, Assembly, Fuel, 2”
1
-9
87903
81381
. Plug, Pipe, Square Head, Std, 1” NPT
4
-10
SE000073
81381
. Sender, Fuel Level, 240-33 Ohms
1
-11
SA000102
81381
. Hose, Assembly, Fuel, 1/2”
1
-12
77006
81381
. Adapter, Elbow, 90 Degree
3
-13
76563
81381
. Cap, Filler, Vent, Cone Filter
1
-14
SA000022
81381
. Assembly, Hose, Fuel Retrun, 150-250 W
1
-15
2021-32-32S
81381
. Adapter, Connector, Male, 2” Tube
2
CD295
Usable
On Code
4-4-3-7
Rev 6
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-3-8
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 4
Engine Air Intake
CD295
4327
4-4-4-1
Orig
Chapter 4
Section 4
Figure 4.1 Engine Air Intake Assembly
4-4-4-2
Orig
CD295
4327
Chapter 4
Section 4
Fig &
Ind #
Part Number
MFR
Code
4.1
Description
Qty
ENGINE AIR INTAKE ASSEMBLY
-1
G112401
81381
Assembly, Air Cleaner, Extended Life Filter
1
-2
P105695
81381
. Element, Filter, Replacement, Extended
Life
1
-3
78603
81381
. Clamp, Worm
4
-4
SP000021
81381
. Elbow, Rubber 90, 7" x 6"
1
-5
P004079
81381
. Band, Mounting (for G112401)
2
-6
SP000022
81381
. Tube, Intake, Engine Air, Series 60
1
-7
P105535
81381
. Elbow, Rubber 90 6"
1
CD295
4327
Usable
On Code
4-4-4-3
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-4-4
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 5
Engine Lubrication System
The engine lubrication system is completely contained within the engine assembly; refer
to the Detroit Diesel Custom Parts Catalogue for detailed parts information on the
engine lubrication system.
Note:
CD295
4327
The Detroit Diesel Custom Parts Catalogue is provided to assist in the
ordering of parts and replacement items.
4-4-5-1
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-5-2
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 6
Engine Cooling System
CD295
4327
4-4-6-1
Orig
Chapter 4
Section 4
Figure 6.1 Fan Drive Parts Assembly
4-4-6-2
Orig
CD295
4327
Chapter 4
Section 4
Table 6.1 Fan Drive Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
6.1
Description
Qty
FAN DRIVE PARTS ASSEMBLY
-1
SP000031
81381
. Fan, 39" 8 Blade Aluminum
1
-2
SW000017
81381
. Weldment, Engine Fan Ring RH
1
-3
SD000079
81381
. Adapter, Engine Fan Ring
1
-4
SW000014
81381
. Weldment, Base Fan Shroud
1
-5
SD000196
81381
. Spacer, Engine Fan
1
-6
A46
81381
. Belts, A Section 46" Pitch Length
Set/3
-7
SW000058
81381
. Weldment, Engine Fan Ring LH
1
CD295
4327
Usable
On Code
4-4-6-3
Orig
Chapter 4
Section 4
Figure 6.2 Jacket Water Parts Assembly
4-4-6-4
Orig
CD295
4327
Chapter 4
Section 4
Table 6.2 Jacket Water Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
6.2
Description
Qty
JACKET WATER PARTS ASSEMB LY
-1
SD000284
81381
. Hose, Jacket Water Return (12.7 & 14.0 L
Series 60)
1
-2
SD000055
81381
. Hose, Water Pump Suction (12.7 & 14.0 L
Series 60)
1
-3
12892909
81381
. Hose, Heater, 1" ID
6.5
-4
2256-4RL
81381
. Hose, De-Aeration 1/4"
3.7
-5
79382
81381
. Clamp, Worm, 1/4" Hose
2
-6
12901644
81381
. Clamp, Worm, 1" Hose
2
-7
MB9425T75S283F
81381
. Clamp, T-Bolt, 3"
4
-8
77741
81381
. Clamp, Nylon, 1"
1
-9
23515397
81381
. Low Coolant Level Switch
1
-10
8924187
81381
. Hose Barb 3/4" NPT x 1" Hose ID, 90
Elbow
1
-11
4738-4-4B
81381
. Aeroquip, Hose Eng 1/4" Barb
1
-12
77746
81381
. Clamp, Nylon, 2-3/4"
1
CD295
4327
Usable
On Code
4-4-6-5
Orig
Chapter 4
Section 4
Figure 6.3 Charge Air Cooler Parts Assembly
4-4-6-6
Rev 4
CD295
6872
Chapter 4
Section 4
Table 6.3 Charge Air Cooler Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
6.3
Description
Qty
CHARGE AIR COOLER PARTS
ASSEMBLY
-1
SW000023
81381
. Weldment, Charge Air Turbo Inlet, DDC
Series 60 12.7 L & 14 L
1
-2
SP000037
81381
. Clamp, Hose, 5-1/2"
4
-3
SD000089
81381
. Hose, Charge Air 5" OD x 3-1/2"
2
-4
SD000086
81381
. Tube, Charge Air Linet Manifold (Series
60 12.7 L & 14 L)
1
-5
SD000531
81381
. Tube, Charge Air Turbo (Cooler Inlet)
(Series 60 12.7 L & 14 L)
1
-6
CT450
81381
. Clamp, Hose, 4-1/2", Caterpillar
4
-7
SD000105
81381
. Hose, Charge Air 4" OD x 8" (3 Bellows)
1
-8
12912045
81381
. Hose, Turbo, 4" ID x 4" LG
1
CD295
6872
Usable
On Code
4-4-6-7
Rev 4
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-6-8
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 7
Engine Exhaust System
CD295
4327
4-4-7-1
Orig
Chapter 4
Section 4
Figure 7.1 Engine Exhaust Parts Assembly
4-4-7-2
Orig
CD295
4327
Chapter 4
Section 4
Table 7.1 Engine Exhaust Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
7.1
Description
Qty
Usable
On Code
ENGINE EXHAUST PARTS ASSEMBLY
-1
SP000014
81381
. Spiral Silencer
1
-2
P270543
81381
. Rain Cap, 6" Exhaust
1
-3
X005833
81381
. Seal Clamp, 5"
1
-4
SD000370
81381
. Exhaust Elbow, Turbo to Muffler
1
-5
23506159
81381
. Clamp, Turbo, 5"
1
-6
SD000369
81381
. Blanket, Heat Dissipation, Muffler
1
Note:
CD295
4327
Refer to the Detroit Diesel Custom Parts Catalogue located in the appendix
of this manual for engine exhaust parts information.
4-4-7-3
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-7-4
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 8
Electrical System
CD295
4327
4-4-8-1
Orig
Chapter 4
Section 4
Figure 8.1 Control Panel, Assembly (Sheet 1 of 2)
4-4-8-2
Rev 2
CD295
5395
Chapter 4
Section 4
Table 8.1 Control Panel, Assembly
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
8.1
SE000038
81381
CONTROL PANEL, ASSEMBLY
1
-1
SE000013
81381
. Faceplate, Control Panel
1
-2
LE000321
81381
. Assembly, Utility Lamp with 24V Bulb
(DS12A, DS12B, DS12C)
3
-3
G2OUB4-FTG7342
81381
. Gauge, Air Temperature, 150-750 °F,
Mechanical
1
-4
12980039
81381
. Gauge, Air Pressure, 0-60 psi, Mechanical
1
-5
310-910
81381
. Gauge, Temperature, 100-250 °F (40-120
°C), 24V, with 24v (P/N 600-826) Bulb,
for use with 10-180 Ohm Sender (GA4,
GA6, GL4, GL6)
2
-6
350-902
81381
. Gauge, Pressure, 0-80 psi, 5 Bar, 24V, with
24V (P/N 600-826) Bulb, for use with 10180 Ohm Sender (GA5, GL5)
1
-7
350-906
81381
. Gauge, Pressure, 0-100 psi, 7 Bar, 24V,
with 24V (P/N 600-826) Bulb, for use with
10-180 Ohm Sender (GA2, GA3, GL2,
GL3)
2
-8
12930787
81381
. Tachometer, 0-3500 rpm, with Hourmeter,
for use with Electronic Engines (DDEC,
etc.) with 24V Bulb (GA7, GL7)
1
-9
MS35058-26
81381
. Switch, Toggle, SPDT, Momentary (OnNone-On) Screw Terminals (S16)
1
-10
301-904
81381
. Gauge, Fuel Level, E-1/2-F, for use with
240-33 Ohm Sender, 240 Ohm with Empty
Tank, with 24V (P/N 600-826) Bulb (GA1,
GL1)
1
-11
332-902
81381
. Voltmeter, 18-32V, with 24V (P/N 600826) Bulb (M1, GL8)
1
-12
LE000062
81381
. Lampholder with Screw Terminals, Oil
Tight, Dialight P/N 125-1310-11-103
(DS1-DS6, DS8-11)
10
-13
LE000064
81381
. Bulb, 24V-DC (Type T3 1/4, 1819) (DS1DS6, DS8-11)
10
-14
LE000063
81381
. Lens, Red, Stovepipe, Internal Fluted,
Dialight P/N 125-1191-403 (DS1, DS3DS6, DS8-DS10)
8
CD295
4327
Usable
On Code
4-4-8-3
Orig
Chapter 4
Section 4
Figure 8.1 Control Panel, Assembly (Sheet 2 of 2)
4-4-8-4
Rev 2
CD295
5395
Chapter 4
Section 4
Table 8.1 Control Panel, Assembly (Cont.)
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
-15
LE000065
81381
. Lens, Amber, Stovepipe, Internal Fluted,
Dialight P/N 125-1193-403 (DS2, DS11)
2
-16
LE000108
81381
. Switch, Toggle, SPST Momentary On
(Off-None-On) Environmentally Sealed,
Cutler Hammer P/N MS24523-30 (S1, S6)
2
-17
LE000249
81381
. Switch, Toggle, 4PDT, Momentary On
(On-None-On). Environmentally Sealed,
Screw Terminals, Cutler Hammer P/N
MS24525-26 (was MS2452) (S13)
1
-18
MS24523-26
81381
. Switch, Toggle, SPST, Momentary Off
(On-None-Off) Environmentally Sealed,
Screw Terminals (S15 - Not Used)
0
-19
SL000003
81381
. Label, Emergency Stop Switch, Yellow
Background
1
-20
IN4006
81381
. Rectifier, 1 Amp, 600 P.R.V., Motorola
(CR1)
1
-21
MS35058-22
81381
. Switch, Toggle, SPST Maintained (OnNone-Off) Screw Terminals (S12)
1
-22
LE 000307
81381
. Switch, Toggle, 4PDT, Maintained, OnNone-On, Environmentally Sealed, Cutler
Hammer P/N MS24525-23 (S2)
1
-23
02011-10
81381
. Jumper, for Adjacent Contact on Same
Deck, for Series 24 Switch (S10)
5
-24
44204LN
81381
. Switch, Rotary Type, Series 24, with 4
Sections, 2 Poles per Section, contact
Assembledge 2, 3 POS. Maintained
Contacts, with Waterproof Mounting Kit
for 0.125 to 0.1875 Thick Panel, 2 Stop
Screws Installed in Stop Holes 2 and 7,
with P/N 02000-11 Oval Handle (S10)
1
-25
3SB02-K4R11
81381
. Switch, Emergency Stop, Red Mushroom
1
CD295
Usable
On Code
4-4-8-5
Rev 6
Chapter 4
Section 4
Figure 8.2 Control Panel, Assembly, Main Relay Panel (Sheet 1 of 2)
4-4-8-6
Orig
CD295
4327
Chapter 4
Section 4
Table 8.2 Control Panel, Assembly, Main Relay Panel
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
8.2
SE000040
81381
CONTROL PANEL, ASSEMBLY, MAIN
RELAY PANEL
1
-1
7022OF
81381
. Time Delay Relay, 24VDC Coil, 1 to 10
Minute Delay on De-energization (TD1)
1
-2
70120C
81381
. Time Delay Relay, 24VDC Coil, 1.5 to 15
Second Delay on Energization (TD2, TD3)
2
-3
SD000390
81381
. Subplate, Relay Mounting (K1, K2, K5K9, K11, K12)
1
-4
SD000391
81381
. Subplate, Relay Mounting (K13A, K13B,
K15-K19)
1
-5
RY4S-ULDC24V
81381
. Relay, 4PDT, 5 Amp, with 24VDC Coil,
with Built-in Indicator Light, Plug-in Type
(K1, K2, K5-K9, K11, K12, K13A, K13B,
K14-K19)
17
-6
SY4S-05
81381
. Socket, Relay, for Plug-in 4PDT Relay,
DIN Rail Snap Mount Type Furn. with (2)
Y778-011 Hand Down Spring Anchors
(Horse Shoe Clips) (K1, K2, K5-K9, K11,
K12, K13A, K13B, K14-K19)
17
-7
SY4S-51F1
81381
. Hold Down Spring, Relay (K1, K2, K5K9, K11, K12, K13A, K13B, K14-K19)
17
-8
BNDN1000
81381
. Relay Mounting DIN Rail, 1 Meter Long
(K1, K2, K5-K9, K11, K12, K13A, K13B,
K14-K19)
1Cut
-9
BNL5
81381
. DIN Rail End Stop (K1, K2, K5-K9, K11,
K12, K13A, K13B, K14-K19)
4
-10
LE000106
81381
. Switch, Toggle, SPDT Momentary On
(On-Off-On) Environmentally Sealed,
Screw Terminals, Cutler Hammer P/N
MS24523-27 (S14)
1
-11
SE000031
81381
. Bracket, Switch Mounting (S14)
1
-12
SE000032
81381
. Nameplate, Store Pressure Setting
(increase/decrease) (S14)
1
-13
SE000033
81381
. Cover, Switch, Tamper Resistant (S14)
1
-14
LE000252
81381
. Resistor, 25 Ohm, 50 Watt, Dale P/N
RH5025 (R12)
1
-15
SE000041
81381
. Assembly, Electrical Harness, Main Relay
Panel
1
CD295
4327
Usable
On Code
4-4-8-7
Orig
Chapter 4
Section 4
Figure 8.2 Control Panel, Assembly, Main Relay Panel (Sheet 2 of 2)
4-4-8-8
Orig
CD295
4327
Chapter 4
Section 4
Table 8.2 Control Panel, Assembly, Main Relay Panel (Cont.)
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
-16
SD000285
81381
. Subplate, Main Back Plate, RelayResistor-Rectifier Mounting
1
-17
SD000392
81381
. Subplate, Terminal Board Mounting (CR2CR18, R1-R11, R13-R25, Z2-Z8, Z10,
Z11)
1
-18
MS37TB31-10
81381
. Marker Strip, 31 Point, Printing Style No.
10 (TB3 - Cut Down to 28 Points)
1
-19
37TB-31
81381
. Terminal Block, 31 Point, with 6-32 Brass
Plated Screws (TB3, TB4 - Cut Down to
28 Points)
2
-20
MS37TB31-40
81381
. Marker Strip, 31 Point, Printing Style No.
40 (TB4 - Cut Down to 28 Points)
1
-21
LE000318
81381
. Voltage Surge Suppressor, Breakdown
Voltage, 33 Volts, 1500 Watts, UniDirectional, General Instruments P/N
1.5KE33A (Z1-Z8, Z10, Z11)
10
-22
LE000131
81381
. Resistor, 220 Ohm, 5 Watt, Ohmite Mfg. P/
N 95J220 (R1-R11, R13-R25)
24
-23
IN4006
81381
. Rectifier, 1 Amp, 600 P.R.V. (CR2-CR18)
17
-24
MS37TB24-VF10
81381
. Marker Strip, 24 Point, Printing Style No.
10 (TB1)
1
-25
37TB-24
81381
. Terminal Block, 24 Point, with 6-32 Brass
Plated Screws (TB1, TB2)
2
-26
MS37TB24-VF40
81381
. Marker Strip, 24 Point, Printing Style No.
40 (TB2)
1
-27
SE000042
81381
. Assembly, Resistor-Rectifier-Suppressor
1
-28
LE000191
81381
. Connector, 19 Contacts (for Female
Sockets) ITT Cannon P/N SLEB19S2S
(P19, P20)
2
-29
LE000192
81381
. Connector, 19 Contacts (for Male Pins)
ITT Cannon P/N SLEB19P4S (Use P/N
LE000138 Pins & P/N LE000195 Cavity
Plugs) (J19, J20)
2
-30
SE000039
81381
. Assembly, Electrical Harness, Control
Panel & ECM Interface
1
-31
SE000006
81381
. Receptacle Assembly, 6 Pin, Male
Contacts (J4)
1
-32
12950802
81381
. Respectable, Male, 35 Pin, ITT Cannon P/
N CA3102R32-7PBA176109 (J3)
1
CD295
4327
Usable
On Code
4-4-8-9
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-10
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Figure 8.3 Compressor, Fuel Tank, and Skid Electrical Components (Sheet 1 of 3)
4-4-8-11 Blank / 4-4-8-12
Orig
CD295
4327
Chapter 4
Section 4
Table 8.3 Compressor, Fuel Tank, and Skid Electrical Components
Fig &
Ind #
Part Number
MFR
Code
8.3
Description
Qty
COMPRESSOR, FUEL TANK, AND SKID
ELECTRICAL COMPONENTS
-1
SE000043
81381
. Assembly, Engine & Compressor
1
-2
1110
81381
. Battery (BT1A, BT1B, BT2A, BT2B)
4
-3
SE000044
81381
. Assembly, Electrical Harness, Engine &
Compressor (NOT SHOWN)
REF
-4
LE000151
81381
. . Connector, Assy., 3 Pin, Female Contacts,
16-18 AWG Wire, 2.03-2.85 mm Wire
O.D., Metri-Pack Type 150 (J11, J13,
J21)
3
-5
LE000152
81381
. . Connector Assy., 4 Pin, Female Contacts,
16-18 AWG Wire, 2.03-2.85 mm Wire
O.D., Metri-Pack Type 150 (J10, J12)
2
-6
SE000027
81381
. . Connector, Assy., 2 Pin, Female Contacts,
16 AWG Wire, 2.03-2.85 mm Wire O.D.,
Metri-Pack Type 280 (J16)
1
81381
. . Connector, Assy., For Optional Engine
Running Beacon, Female (J17)
1
-7
-8
SM-2C-12F-AU
81381
. Switch, Pressure, SPDT, 5 Amp, Gold
Plated, Contacts Adjusted to Close at 12
psi on Falling Pressure, 1/8-27 NPT Male
Threads (S5)
1
-9
360-003
81381
. Sender, 0-80 psi, 10-180 Ohm, 1/8-27 NPT
Male Threads (SE5)
1
-10
360-094
81381
. Sender, 250 °F, 10-180 Ohm, 3/8-18 NPT
Male Threads (SE6)
1
-11
TT-2A-0100176R
81381
. Switch, Temperature, N/O Contact
Adjusted to Close at 176 °F on Rising
Temp., with 3/8 NPT 1" Long Male
Threads, 8-32 Electrical Connections (S3)
1
-12
SE000034
81381
. Kit, Low Fuel Level, with Switch & Blue
Beacon Option (OPTION)
REF
-13
SE000045
81381
. . Assembly, Electrical Harness, Low Fuel
Level Beacon Option
1
-14
LE000005
81381
. . Lamp Assembly, Flashing Incandescent,
24V, with Blue Lens (Optional) (DS7,
FL1)
1
81381
. . Flasher, Beacon, Low Level Fuel, 24V
(Optional) (FL1)
1
-15
CD295
4327
Usable
On Code
4-4-8-13
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-14
Orig
CD295
4327
Chapter 4
Section 4
Figure 8.3 Compressor, Fuel Tank, and Skid Electrical Components (Sheet 2 of 3)
4-4-8-15 Blank / 4-4-8-16
Orig
CD295
4327
Chapter 4
Section 4
Table 8.3 Compressor, Fuel Tank, and Skid Electrical Components (Cont.)
Fig &
Ind #
MFR
Code
Description
Qty
81381
. . Relay, 40A Control, 24VCD Coil, Potter
& Brumfield P/N VF4-15H11 (Optional)
(K4)
1
-17
81381
. . Resistor, Burden, 220 Ohm (Optional)
(R26)
1
-18
81381
. . Plug, For Low Level Fuel Beacon, Male
(Optional) (P13)
1
-16
Part Number
LE000018
-19
SE000046
81381
. Assembly, Comp. Low Discharge Pressure
Pilot Assist Switches
1
-20
SE000047
81381
. . Assembly, Electrical Harness,
Compressor Low Discharge Pressure
Pilot Assist Switches (P21)
1
-21
23518254
81381
. . Transducer, Air Pressure, 0-300 psig, 0.54.5VDC Operating Voltage (APTD)
1
-22
SM-2C-34F/BT
81381
. . Switch, Pressure, SPDT, Contacts Adjust
to Actuate at 34 psi on Falling Pressure,
1/8-27 NPT Male Threads (S18)
1
-23
23520025
81381
. . Switch, Pressure, SPDT, Contacts Adjust
to Actuate at 20 psi on Falling Pressure,
1/8-27 NPT Male Threads (S17)
1
-24
81381
. . Plug, For Switches S17 and S18, Male
(P21)
1
-25
81381
. Kit, Engine Running, with Switch and
Amber Beacon Option (OPTION)
REF
-26
81381
. . Assembly, Electrical Harness, Engine
Running Beacon Option
1
-27
81381
. . Lamp, Assembly, Flashing Incandescent,
24V, with Amber Lens (Optional) (DS13,
FL2)
1
-28
81381
. . Flasher, Beacon, Engine Running, 24V
(Optional) (FL2)
1
-29
81381
. . Relay, 24VDC Coil, Engine Running
Beacon (Optional) (K20)
1
-30
81381
. Resistor, Burden, 220 Ohm (Optional)
(R27)
1
-31
81381
. Plug, For Low Level Fuel Beacon, Male
(Optional) (P17)
1
CD295
4327
Usable
On Code
4-4-8-17
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-18
Orig
CD295
4327
Chapter 4
Section 4
Figure 8.3 Compressor, Fuel Tank, and Skid Electrical Components (Sheet 3 of 3)
4-4-8-19 Blank / 4-4-8-20
Orig
CD295
4327
Chapter 4
Section 4
Table 8.3 Compressor, Fuel Tank, and Skid Electrical Components (Cont.)
Fig &
Ind #
-32
Part Number
MFR
Code
SE000007
Description
Qty
. Connector Assy., 3 Pin, Female Contacts
(P6)
1
12065287
81381
. . Connector, 3 Pin, Female, with Cable
Seal (P6)
REF
12103881
81381
. . Terminal, Female, for 16-14 AWG Wire
Size (P6)
REF
-33
12950803
81381
. Plug, Female, 35 Pin, ITT Cannon P/N
CA3106E32-7SBF80A (P3, NOT
SHOWN - LOCATED ON CONTROL
PANEL)
REF
-34
12911262
81381
. Switch, Air Temperature, N/O Contact
Adjusted to Close at 460 °F on Rising
Temp. (S4)
1
-35
837-N1
81381
. Well, Separable Temperature (S4)
1
-36
81381
. Solenoid, Air Packs Mode Valve, N/C
Orifice, 24V Coil (L2)
1
-37
81381
. Solenoid, Low Pressure Assist; Adds
Additional Pilot Pressure to Air Comp.
Unloader Valve to Increase Discharge
Pressure, Air Packs Mode Valve, N/C
Orifice, 24V Coil (L4)
1
-38
81381
. Solenoid, Compressor Jet Start Mode
Valve, N/C Orifice, 24V Coil
(L3)
1
-39
LE000157
81381
. Connector Assy., 4 Pin, Male Contacts, 16- REF
18 AWG Wire, 2.03-2.85 mm Wire O.D.,
Metri-Pack Type 150 (P10 - Ref.,
Furnished by Vendor)
-40
SE000052
81381
. Plug, For Switch S7, Male (P11)
1
-41
SE000052
81381
. Assembly, Low Fuel Level Warning
Switch Option (P11, S7)
1
-42
SE000048
81381
. Assembly, Fuel Level Sender, including
Harness (SE1)
1
-43
SE000050
81381
. Assembly, Low Fuel Level Shutdown
Switch Option, Includes Harness (S8)
1
-44
81381
. Plug, For Switch S8, Male (P12)
1
-45
81381
. Plug, For Sender SE1, Male (P16)
1
CD295
4327
Usable
On Code
4-4-8-21
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-22
Orig
CD295
4327
Chapter 4
Section 4
Figure 8.4 Engine Electrical Components (Sheet 1 of 2)
4-4-8-23 Blank / 4-4-8-24
Orig
CD295
4327
Chapter 4
Section 4
Table 8.4 Engine Electrical Components
Fig &
Ind #
Part Number
MFR
Code
8.4
-1
Description
Qty
ENGINE ELECTRICAL COMPONENTS
23515397
-2
81381
. Assembly, Sensor, Low Coolant Level,
Detroit Diesel P/N 23520380, 1/4 NPT
Fitting, Variable Resistance Type, Furn.
with Electrical Connector Kit (LT1, P7)
1
81381
. Plug, Coolant Level Probe, Female (P7)
1
-3
SE000044
81381
. Assembly, Electrical Harness, Engine &
Compressor (NOT SHOWN)
REF
-4
19010182
81381
. Alternator, With Internal Voltage
Regulator (Battery Charging) 24V (G1)
1
-5
323-093
81381
. Sender, 250 °F, 10-180 Ohm, 1/2-14 NPT
Male Threads (SE4)
1
-6
360-086
81381
. Sender, 0-100 psi, 10-180 Ohm, 1/8-27
NPT Male Threads (SE2, SE3)
2
-7
240-903
81381
. Kit, Bushing, with 1 each Female 1/8-27 to
1/4, 3/8, & 1/2 Bushings (SE2, SE3)
2
-8
24063-09
81381
. Relay (Contactor) 24VDC Coil, N/O SPST
(K3)
1
-9
LE000318
81381
. Voltage Surge Suppressor, Breakdown
voltage, 33 Volts, 1500 Watts, UniDirectional, General Instruments P/N
1.5KE33A (Z9)
1
-10
SE000035
81381
. Assembly, Engine Fuse Box
1
-11
SE000008
81381
. . Assembly, Fuse Block, 4 Pole, for Type
ATO Fuses (XFA)
1
-12
SE000009
81381
. . Box, NEMA 3R, 6" Wide x 8" High x 4"
Deep (F1-F4, XFA)
1
-13
SE000010
81381
. . Cover, Nameplate, Fuse Identification
(F1-F4) (NOT SHOWN)
1
-14
CGB193
81381
. . Cable Fitting (NOT SHOWN)
2
-15
BL-50
81381
. . Lock Nut (NOT SHOWN)
4
-16
257010
81381
. . Fuse, 10 Amp Automotive Blade Type,
Type ATO (F1)
1
-17
257005
81381
. . Fuse, 5 Amp Automotive Blade Type,
Type ATO (F2)
1
CD295
4327
Usable
On Code
4-4-8-25
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-26
Orig
CD295
4327
Chapter 4
Section 4
Figure 8.4 Engine Electrical Components (Sheet 2 of 2)
4-4-8-27 Blank / 4-4-8-28
Orig
CD295
4327
Chapter 4
Section 4
Table 8.4 Engine Electrical Components (Cont.)
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
-18
257015
81381
. . Fuse, 25 Amp, Automotive Blade Type,
Type ATO (F3, F4)
2
-19
SD000238
81381
. . Bracket, Fuse Box (K3, Fuse Box -- F1F4, XFA)
1
-20
10478980
81381
. Motor, Engine Starting, 24V (B1)
1
81381
. Solenoid, Engine Starting, 24V (L1)
1
-21
-22
23520025
81381
. Switch, Pressure, SPDT, Contacts adjust to
Actuate at 20 psi, 1/8-27 NPT Male
Threads (S11)
1
-23
SE000001
81381
. Connector Assy., 5 Pin, Female, Series
280, Metri-Pack (P8)
1
-24
SE000004
81381
. Connector Assy., 30 Pin, Female (P5)
1
81381
. Fuse, In-Line, 5 Amp (F5, F6)
2
81381
. Fuseholder, In-Line, with Protective Cap,
Rated up to 20 Amps (XFB, XFC)
2
-25
-26
CD295
4327
FHAC-1
Usable
On Code
4-4-8-29
Orig
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-30
Orig
CD295
4327
Chapter 4
Section 4
Figure 8.5 Engine ECM and Fuse Box
4-4-8-31 Blank / 4-4-8-32
Orig
CD295
4327
Chapter 4
Section 4
Table 8.5 Engine ECM and Fuse Box
Fig &
Ind #
Part Number
MFR
Code
8.5
Description
Qty
ENGINE ECM AND FUSE BOX
-1
SE000039
81381
. Assembly, Electrical Harness, Control
Panel & ECM Interface
1
-2
SE000023
81381
. Connector Assy., 2 Pin, Male Contacts, 12
AWG Wire, 2.81-3.49 mm Wire O.D.,
Metri-Pack Type 280 (P15)
1
-3
SE000036
81381
. Assembly, Electrical Harness, Fuse Box to
Battery
1
-4
81381
. . Connector Assy., 2 Pin, Female (J15)
1
-5
81381
. . Connector Assy., 4 Pin, Female (J14)
1
-6
SE000017
81381
. Connector Assy., 4 Pin, Male Contacts, 12
AWG Wire, 2.81-3.49 mm Wire O.D.,
Metri-Pack Type 280 (P14)
1
-7
SE000035
81381
. Assembly, Engine Fuse Box
1
-8
SE000008
81381
. . Assembly, Fuse Block, 4 Pole, for Type
ATO Fuses (XFA)
1
-9
SE000009
81381
. . Box, NEMA 3R, 6" Wide x 8" High x 4"
Deep (F1-F4, XFA)
1
-10
SE000010
81381
. . Cover, Nameplate, Fuse Identification
(F1-F4) (NOT SHOWN)
1
-11
CGB193
81381
. . Cable Fitting (NOT SHOWN)
2
-12
BL-50
81381
. . Lock Nut (NOT SHOWN)
4
-13
257010
81381
. . Fuse, 10 Amp Automotive Blade Type,
Type ATO (F1)
1
-14
257005
81381
. . Fuse, 5 Amp Automotive Blade Type,
Type ATO (F2)
1
-15
257015
81381
. . Fuse, 15 Amp, Automotive Blade Type,
Type ATO (F3, F4)
2
-16
SE000015
81381
. Assembly, Electrical Harness, Interface,
Power to DDEC
1
-17
SE000002
81381
. . Connector Assy., 2 Pin, Female (J9)
1
-18
SE000003
81381
. Connector Assy., 2 Pin, Male (P9)
1
-19
SE000001
81381
. Connector Assy., 5 Pin, Female, Series
280, Metri-Pack (P8)
1
-20
SE000004
81381
. Connector Assy., 30 Pin, Female (P5)
1
CD295
4327
Usable
On Code
4-4-8-33
Orig
Chapter 4
Section 4
Figure 8.6 Battery Parts Assembly
4-4-8-34
Rev 2
CD295
5395
Chapter 4
Section 4
Table 8.6 Battery Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
8.6
Description
Qty
BATTERY PARTS ASSEMBLY
-1
6S1375-1
81381
. Deck, Battery Plywood
1
-2
1110
81381
. Battery, 12VDC, Hybrid Lead
4
-3
2MJ7
81381
. Cable, Battery Jumper 2 GA.x7"
4
-4
12922244
81381
. Cover, Battery Assembly
1
-5
NO NUMBER
COML
. Nut, 5/16" UNC
1
-6
70018
81381
. Bolt, J
2
-7
NO NUMBER
COML
. Flat Washer, 5/16" Diameter
1
-8
SW000087
81381
. Tray, Battery
1
CD295
5395
Usable
On Code
4-4-8-35
Rev 2
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-8-36
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 9
Air Compressor Cooling and Lubrication
CD295
4327
4-4-9-1
Orig
Chapter 4
Section 4
Figure 9.1 Lube Oil GHH Compressors
4-4-9-2
Orig
CD295
4327
Chapter 4
Section 4
Table 9.1 Lube Oil GHH Compressors
Fig &
Ind #
Part Number
MFR
Code
9.1
Description
Qty
LUBE OIL GHH COMPRESSORS
-1
SD000108
81381
. Valve, thermostatic, 120 °F Crack, Bruning
1
-2
SD000177
81381
. Manifold, Compressor, Oil Temperature
Sensors
1
-3
GG106-NP-12-16
81381
. Adapter, Straight, JIC12M - BSPP16M
2
-4
76941
81381
. Adapter, Straight, SAE16M - JIC16M
4
-5
2216-12-16S
81381
. Adapter, Straight, NPT12F - SAE16M
1
-6
78175
81381
. Nipple, Close, NPT12M - NPT12M
1
-7
78904
81381
. Adapter, Straight, NPT12M - JIC12M
3
-8
GG106-NP-12-08
81381
. Adapter, Straight, JIC12M - BSPP08M
1
-9
SA000018
81381
. Assembly, Hose, Compressor Pump to
Thermal Valve
1
-10
SA000019
81381
. Assembly, Hose, Thermal Valve to Oil
Cooler
1
-11
SA000020
81381
. Assembly, Hose, Oil Cooler to Oil
Manifold
1
-12
SA000021
81381
. Assembly, Hose, Oil Manifold to
Compressor
1
-13
p/o compressor
. Pump, Lube Oil
1
-14
SP000026
. Cooler, Lube Oil
1
CD295
5395
Usable
On Code
81381
4-4-9-3
Rev 2
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-9-4
Orig
CD295
4327
Chapter 4, Section 4
Chapter 4
Section 4
Group 10
Compressor Air Distribution and Regulation System
CD295
6657
4-4-10-1
Rev 3
Chapter 4
Section 4
Figure 10.1 Discharge/Unloader Parts Assembly (Sheet 1 of 2)
4-4-10-2
Rev 3
CD295
6657
Chapter 4
Section 4
Table 10.1 Discharge/Unloader Parts Assembly
Fig &
Ind #
Part Number
MFR
Code
10.1
Description
Qty
DISCHARGE/UNLOADER PARTS ASSY
-1
SP000011
81381
. Silex Absorptive Silencer
1
-2
H000349
81381
. Discharge Silencer Mounting Band
1
-3
X005832
81381
. Seal Clamp, 4"
2
-4
SW000021
81381
. Weldment, Flange, Unloader to Silencer
1
-5
SD000216
81381
. Rod, Tie, Compressor Discharge
2
-6
SW000002
81381
. Weldment, Discharge Manifold
1
-7
SA000008
81381
. Assembly, Control, Unloader
1
-8
SG000008
81381
. Group, Valve Unloader
1
-9
SD000073
81381
. Discharge Tube, Unloader Side
1
-10
CT450
81381
. Clamp, Hose, 4-1/2", Caterpillar
2
-11
SD000105
81381
. Hose, Charge Air 4" OD x 8" (3 Bellows)
1
-12
SD000074
81381
. Discharge Tube, Silencer Side
1
-13
SD000083
81381
. Mount, Vibration, 507-1-N-S
3
-14
SD000084
81381
. Washer, Snubbing, R18733-1
3
-15
12950251
81381
. Valve, Ball, 3/4" Internal Pipe
1
-16
78175
81381
. Nipple, Pipe, 3/4" MNPT
1
-17
88110
81381
. Elbow, Pipe, Street, 150# 90°, 3/4" NPT
1
-18
12950531
81381
. Adapter, Flanged, Air Start Hose
1
-19
97904
81381
. Valve, 4" Butterfly Discharge
1
-20
SD000006
81381
. Gasket, Flange
1
-20
SD000214
81381
. Gasket, Flange
1
-21
57AC518
81381
. Rain Cap, Air Start Silencer
1
-22
SD000109
81381
. Valve, Quick Exhaust 3/8" NPT
1
-23
12970123
81381
. Coupling, Dresser, 8" Style 38
1
-24
SW000019
81381
. Weldment, Pipe, Supply, 250
1
-25
SW000037
81381
. Weldment, Discharge, CD42S
1
-26
78890
81381
. Adapter, #4 MNPT X #4 MJIC
1
-27
SA000034
81381
. Assembly, Hose, Unloader Pilot Air
1
CD295
6657
Usable
On Code
150/180
4-4-10-3
Rev 3
Chapter 4
Section 4
Figure 10.1 Discharge/Unloader Parts Assembly (Sheet 2 of 2)
4-4-10-4
Rev 3
CD295
6657
Chapter 4
Section 4
Table 10.1 Discharge/Unloader Parts Assembly (Cont.)
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
-28
169X6X6
81381
. Fitting Brass, 3/8" NPT x 3/8" Compress.,
90° Elbow
1
-29
121901382
81381
. Tube, Copper, 3/8" dia.
2.5
-30
56AA546
81381
. Gasket, Unloader Valve, Inlet
1
-31
56AB252
81381
. Gasket, Unloader Valve, Outlet
1
-32
SD000422
81381
. Nipple, 3”, Close
1
-33
SD000421
81381
. Elbow, 3”, 90 Degree
2
-34
SD000423
81381
. Nipple, 3”, 6” Long
1
-35
87067
81381
. Valve, Relief, Air, 3”
1
-36
93291
81381
. Bolt, M20-2.5 x 45 mm, GR 8.8 min. HHCS,
Torque to 90 ft-lb (NOT SHOWN)
12
-37
SW000115
81381
. Weldment, Knuckle Valve Support
1
-38
SD000422
81381
. Pipe Nipple, Close, 3”
1
-39
88090
81381
. Elbow, 45 Degree, 3”
1
-40
SD000519
81381
. Hose, 3.5”
Ref.
-41
SD000520
81381
. Hose Connector (Not Shown)
2
-42
69726
81381
. Clamp (Not Shown)
4
CD295
6657
Usable
On Code
4-4-10-5
Rev 3
Chapter 4
Section 4
Figure 10.2 Unloader Valve Assembly
4-4-10-6
Rev 3
CD295
6657
Chapter 4
Section 4
Table 10.2 Unloader Valve Assembly
Fig &
Ind #
Part Number
MFR
Code
Description
Qty
10.2
57AC884
81381
UNLOADER VALVE ASSEMBLY
REF
-1
58AB052
81381
Housing, Unloader
1
-2
55AA532
81381
Unloader Cylinder Mount
1
-3
NO NUMBER
Nut, Jam, 5/8-24"
1
-4
58AA050
81381
Bushing 3-1/2" Long
1
-5
55AA533
81381
Shaft, Unloader Valve
1
-6
58AA051
81381
Disc, Unloader Valve*
1
-7
97905
81381
Actuator, Unloader Valve
1
-8
71068
81381
Washer, Flat, 3/8"
1
-9
74626
81381
Washer, Lock, 3/8"
1
-10
94859
81381
Bolt, Hex Head, 3/8-24 x 1"
1
-11
56AB252
81381
Gasket, Unloader Housing
1
-12
73821
81381
Bolt, 1/2-13 x 1-1/2", Grade 5 (NOT
SHOWN)
1
-13
73807
81381
Washer, Lock, 1/2" (NOT SHOWN)
1
-14
12313910
81381
Dampener, Pad, Unloader Valve (NOT
SHOWN)
1
CD295
6657
COML
Usable
On Code
4-4-10-7
Rev 3
Chapter 4
Section 4
Figure 10.3 Compressor Air Cleaner Assembly
4-4-10-8
Rev 3
CD295
6657
Chapter 4
Section 4
Table 10.3 Compressor Air Cleaner Assembly
Fig &
Ind #
Part Number
MFR
Code
10.3
Description
Qty
COMPRESSOR AIR CLEANER
ASSEMBLY
-1
SP000015
81381
Air Cleaner Assembly
1
-2
484P
81381
Filter, Air, Replacement
1
-3
SD000005
81381
Gasket, Flange, 250 mm Din PN 6
1
-4
93290
81381
Bolt, M16-2.0 x 40 mm, GR 8.8 min.
HHCS, Torque to 60 ft-lb (NOT SHOWN)
12
CD295
6657
Usable
On Code
4-4-10-9
Rev 3
Chapter 4
Section 4
This Page Intentionally Left Blank
4-4-10-10
Rev 3
CD295
6657
Chapter 5
TOC
Chapter 5
Drawings
TABLE OF CONTENTS
Description
Drawing Number
Light, Jet Start Timer TMD Air Starts . . . . . . . . . . . . . . . . . . . . . . . . . SA000206
Circuit, Engine Warm-Up TMD Air Starts . . . . . . . . . . . . . . . . . . . . . . SA000207
Counter and Label Emergency TMD Air Starts . . . . . . . . . . . . . . . . . . SA000209
Nameplates and Stenciling- TMD Series Air Starts . . . . . . . . . . . . . . . SL000004
Nameplate - CE TMD/TRD Series Air Starts . . . . . . . . . . . . . . . . . . . . SL000005
Schematic, Air Start Control Circuit with DDEC IV Engine . . . . . . . . . . SS000009
Wiring Diagram, Air Start Control Circuit with DDEC IV Engine . . . . . . SS000010
Control Panel Layout Air Start Unit with DDEC IV Engine . . . . . . . . . . SS000011
CD295
6657
5-TOC-i
Rev 3
Chapter 5
TOC
This Page Intentionally Left Blank.
5-TOC-ii
Rev 3
CD295
6657
Chapter 6
TOC
Chapter 6
Optional Equipment and Manufacturer’s Reference Data
The Table of Contents for Chapter 6 lists all the options which are offered. This chapter
is divided into sections and each section covers one option.
Information in Chapter 6 is to be used in conjunction with Chapters 1 through 5. Each
section of Chapter 6 covers additional information that is not covered in the main text.
For example, if an option changes or adds to the operation procedure, the new procedure
will be included in the appropriate option section of Chapter 6. Instructions in Chapter 6
supersede those corresponding instructions in Chapters 1 through 5.
TABLE OF CONTENTS
Option/
Description
Paragraph
Page
1
1.1
1.2
1.3
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
2
2.1
2.2
2.3
TR/TMD-150/180/250 Air Start Unit Low Fuel Level in Tank . . . . . . 6-2-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1
3
3.1
3.2
Air Delivery Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1
4
4.1
4.2
4.3
Flashing Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1
5
5.1
5.2
5.3
Jet Start Mode Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
CD295
6657
6-TOC-i
Rev 3
Chapter 6
TOC
6
6.1
6.2
6.3
Engine Warm-Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1
7
7.1
7.2
7.3
Counter and Label-Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
6-TOC-ii
Rev 3
CD295
6657
Chapter 6
MANUFACTURER’S DATA
The following is a list of manufacturer’s service literature included in the appendices of
this manual.
A
GHH-Rand Service Manual for Oil Free Single Stage Air Compressor
(Type CD26S, CD42S, and CD72S) (with Installation Drawings and Performance Data)
GHH-Rand Spare Parts List CD26S Gear Set*
GHH-Rand Spare Parts List CD42S Gear Set**
B
Detroit Diesel Engine Operators Guide, Series 60 (6SE484 9901)
- DDEC® III/IV System Diagnostic Codes and MPSI Reader Functions (7SE414 9710)
- Detroit Diesel 1999 Warranty Information (19SE99 9902)
- Detroit Diesel Series 60 DDEC III Driving Tips (25ST161-1 9403)
Detroit Diesel Custom Parts Catalogue (Eng. Model No. 6063TK33)
Detroit Diesel Custom Parts Catalogue (Eng. Model No. 6063HK33)
Detroit Diesel Series 60 Service Manual (6SE483) (Two volumes, shipped separately)
Detroit Diesel DDEC III/IV Troubleshooting Guide (6SE497 9711) (One volume, shipped
separately)
*CD26S Gear Set applies to TR/TMD-150/180 Air Start Units.
**CD42S Gear Set applies to TR/TMD-250 Air Start Unit.
CD295
6657
--iii
Rev 3
Chapter 6
This Page Intentionally Left Blank
--iv
Rev3
CD295
6657
Chapter 6
Option 1
Chapter 6, Option 1
Fuel Filter/Water Separator
1.1
DESCRIPTION
1.1.1
1.2
1.3
The fuel filter/water separator uses a primary-stage separator, a secondary-stage,
and a final-stage filtration process. It has an internal check valve to prevent
bleed-back, and a turbine centrifuge. The clear bowl is convenient for visual
checks for contaminant in the fuel.
MAINTENANCE
1.2.1
The bowl must be drained before the contaminants reach the bottom of the
centrifuge assembly. See Figure 6.4. If the inlet to the filter/separator is plugged,
disconnect the inlet line, open drain valve (1), and blow out with compressed air.
In case of severe stoppage, remove the bowl and centrifuge (4) and clean with
compressed air.
1.2.2
To change the element (See Figure 6.4), remove T-handle (14) and lid (12).
Remove element (10) by pulling bail (wire handle). Install new element, with a
turning motion, over the center return table
PARTS LIST
1.3.1
CD295
4327
Refer to Table 1.1.
6-1-1
Orig
Chapter 6
Option 1
Figure 1.1
6-1-2
Orig
Standard Fuel Kit Assembly
with Racor Filter Option
CD295
4327
Chapter 6
Option 1
Ta ble 1 . 1
Fig &
Ind #
St a n d a rd F u e l K i t A s s e m bly w i t h R a c o r F i l t e r O p t i o n
( R e fe r t o F i g u r e 1 . 1 )
Part Number
MFR
Code
1.1
Description
Qty
STANDARD FUEL KIT ASSEMBLY
WITH RACOR FILTER OPTION
-1
SA000037
81381
Assembly, Fuel Tank (Trailer Unit)
1
-2
78898
81381
. Adapter, Connector, Male, Aeroquip 20218-8S
1
-3
232B-4PP
81381
. Valve, Check, 1/2” NPT
1
-4
2083-12-8S
81381
. Adapter, Nipple, 3/4” MNPT x 1/2” MNPT
1
-5
SA000023
81381
. Assembly, Hose, Fuel Pick-UP, 150-250
w/ S60
1
-6
78894
81381
. Adapter, Connector, Male, Aeroquip 20216-8S
1
-7
23518482
81381
. Filter, Fuel, Secondary
1
-8
2089-4-2S
81381
. Elbow, Reducing 90, Aeroquip 2089-4-2S
1
-9
208007-4-4S
81381
. Cross, Aeroquip 208007-4-2S
1
-10
2081-4-2S
81381
. Bushing, Reducer Aeroquip 2084-4-2S
1
-11
77006
81381
. Adapter, Elbow 90 Degree, Aeroquip
2024-12-8S
1
-12
SA000022
81381
. Assembly, Hose, Fuel Return, 150-250 w/
S60
1
-13
77738
81381
. Clamp, Support, Hose, Clamp ID=.938
1
-14
SW000006
81381
. Mount/Fuel Tank
1
-15
210292-8S
81381
. Cap, Aeroquip 210292-8S
1
-16
900599-8S
81381
. Plug, Swivel, #8, Aeroquip 900599-8S
1
-17
76927
81381
. Adapter, Connector, Aeroquip 202702-108S
2
-18
1000FG
81381
. Filter, Fuel/Water Separator
1
-19
SD000072
81381
. Bracket, Racor
1
-20
SA000024
81381
. Assembly, Hose, Fuel Tank-Racor
1
CD295
5395
Usable
On Code
6-1-3
Rev 2
Chapter 6
Option 1
Figure 1.2 Twin Fuel Tank Kit Assembly with Racor Filter Option
6-1-4
Rev 2
CD295
5395
Chapter 6
Option 1
Table 1.2 Twin Fuel Tank Kit Assebmly with Racor Filter Option
(Refer to Figure 1.2)
Fig &
Ind #
Part Number
MFR
Code
1.1
Description
Qty
STANDARD FUEL KIT ASSEMBLY
WITH RACOR FILTER OPTION
-1
SA000082
81381
Assembly, Fuel Tank (Trailer Unit)
2
-2
2025-6-8S
81381
. Adapter, Elbow, 1/2” Tube To 3/8”
1
-3
87046
81381
. Valve, Check, In-Line, 3/8” NPT
1
-4
2083-12-6S
81381
. Fitting, Aeroquip, Pipe-To-Pipe
1
-5
SA000023
81381
. Assembly, Hose, Fuel Pick-UP, 150-250
w/ S60
1
-6
78894
81381
. Adapter, Connector, Male, Aeroquip 20216-8S
1
-7
23518482
81381
. Filter, Fuel, Secondary
1
-8
2089-4-2S
81381
. Elbow, Reducing 90, Aeroquip 2089-4-2S
1
-9
208007-4-4S
81381
. Cross, Aeroquip 208007-4-2S
1
-10
2081-4-2S
81381
. Bushing, Reducer Aeroquip 2084-4-2S
1
-11
77006
81381
. Adapter, Elbow 90 Degree, Aeroquip
2024-12-8S
1
-12
SA000022
81381
. Assembly, Hose, FUel Return, 150-250 w/
S60
1
-13
77738
81381
. Clamp, Support, Hose, Clamp ID=.938
1
-14
SW000006
81381
. Mount/Fuel Tank
1
-15
210292-8S
81381
. Cap, Aeroquip 210292-8S
1
-16
900599-8S
81381
. Plug, Swivel, #8, Aeroquip 900599-8S
1
-17
76927
81381
. Adapter, Connector, Aeroquip 202702-108S
2
-18
1000FG
81381
. Filter, Fuel/Water Separator
1
-19
SD000072
81381
. Bracket, Racor
1
-20
SA000024
81381
. Assembly, Hose, Fuel Tank-Racor
1
CD295
5395
Usable
On Code
6-1-5
Rev 2
Chapter 6
Option 1
This Page Intentionally Left Blank
6-1-6
Rev 2
CD295
5395
Chapter 6
Option 2
Chapter 6, Option 2
TR/TMD-150/180/250 Air Start Unit Low Fuel Level in Fuel Tank
2.1
DESCRIPTION
2.1.1
2.2
OPERATION
2.2.1
2.3
The low fuel level option provides the operator of the air start unit with a
warning of when the fuel drops below a predetermined level in the fuel tank.
A low fuel level switch (S7) is located in the day tank and is activated in the
event the fuel drops below a predetermined level. The switch (S7) closes, causing
the low fuel level relay (K4) and LOW FUEL LEVEL lamp (DS7) to energize.
The blue flashing lamp that is mounted on the roof of the unit provides a visual
indication the fuel tank is low on fuel. Relay (K4) and LOW FUEL LEVEL lamp
(DS7) will remain energized until the TROUBLE RESET switch (S15) on the
control panel is actuated. The low fuel level shutdown switch (S8) will cause the
unit to shut down once the fuel level reaches an unsafe running level in the fuel
day tank.
PARTS LIST
2.3.1
CD295
4327
Refer to Table 2.1 for a complete list of component parts.
6-2-1
Orig
Chapter 6
Option 2
Ta ble 2 . 1
Fig &
Ind #
L ow F u e l L ev e l O p t i o n
Part Number
MFR
Code
2.1
Description
Qty
LOW FUEL LEVEL OPTION
-1
SE000034
81381
Kit, Low Fuel Level, with Switch and Blue
Beacon
1
-2
SE000045
81381
. Harness Assembly, Electrical, Low Fuel
Level
1 ea.
-3
SE000029
81381
. Connector Assembly, 2 Pin Male
1 ea.
-4
6T41-0000379
81381
. Sender, Fuel Level, 240-30
1 ea.
-5
SE000050
81381
. Switch Assembly, Low Fuel Level
Shutdown (S8)
1 ea.
-6
SE000012
81381
. Switch Assembly, Low Fuel Level Float
Position
1 ea.
-7
SE000052
81381
. Switch Assembly, Low Fuel Level
Warning
1 ea.
-8
SE000053
81381
. Harness Assembly, Low Fuel Level
Warning
1 ea.
6-2-2
Orig
Usable
On Code
CD295
4327
Chapter 6
Option 3
Chapter 6, Option 3
Air Delivery Hoses
3.1
DESCRIPTION
3.1.1
3.2
The function of the air delivery hose is to direct the compressor discharge air to
the aircraft. Air delivery hoses are available in lengths of 20, 30, 40, 50, and 60
feet.
PARTS LIST
3.2.1
CD295
4327
Refer to Table 3.1 for a complete list of component parts.
6-3-1
Orig
Chapter 6
Option 3
Figure 3.1
6-3-2
Orig
Air Delivery Hoses
CD295
4327
Chapter 6
Option 3
Ta ble 3 . 1
Fig &
Ind #
Ai r D e l i v e r y H o s e s ( R e fe r t o F ig u r e 3 . 1 )
Part Number
MFR
Code
3.1
Description
Qty
Usable
On Code
AIR DELIVERY HOSES
-1
81585
81381
. Hose Assembly, Air Delivery, 20 ft
1
-2
82652
81381
. Hose Assembly
1
-3
12871501-1
81381
. Hose
1
-4
58AA298-1
81381
. Fitting, Air Hose, Female
1
-5
58AA298-2
81381
. Fitting, Air Hose, Male
1
-6
81681
81381
. Clamp, T-Bolt
4
-7
81680
81381
. Clamp, V-Type
2
-8
81666
81381
. Nozzle, Aircraft Connect
1
ITEMS NOT SHOWN
-9
81813
81381
. Hose Assembly, Air Deliver, 30 ft
1
-10
82650
81381
. Hose Assembly
1
-11
12871501-2
81381
. Hose
1
-12
12882976
81381
. Hose Assembly, Air Delivery, 40 ft.
1
-13
12882975
81381
. Hose Assembly
1
-14
12871501-5
81381
. Hose
1
-15
81814
81381
. Hose Assembly, Air Deliver, 50 ft
1
-16
82651
81381
. Hose Assembly
1
-17
12871501-3
81381
. Hose
1
-18
12873581
81381
. Hose Assembly, Air Delivery, 60 ft.
1
-19
12873579
81381
. Hose Assembly
1
-20
12871501-4
81381
. Hose
1
CD295
4327
6-3-3
Orig
Chapter 6
Option 3
This Page Intentionally Left Blank
6-3-4
Orig
CD295
4327
Chapter 6
Option 4
Chapter 6, Option 4
Engine Running Beacon
6.1
DESCRIPTION
6.1.1
6.2
OPERATION
6.2.1
6.3
The flashing engine running beacon option provides a visual warning when the
unit is operating. The amber lamp is mounted on the unit’s roof.
The engine fuel pressure sensor (SE2) closes at 5 psi which energizes the relay
(K20) and flasher (FL2) that, in turn, energize the flashing beacon (DS13). The
system is protected by a 5-amp fuse (F6) which is located inline near the battery
starting motor (B1) and the engine starting solenoid (L1).
PARTS LIST
6.3.1
CD295
4327
Refer to Table 4.1 for a complete list of component parts.
6-4-1
Orig
Chapter 6
Option 4
Figure 4.1
6-4-2
Orig
Engine Running Beacon
CD295
4327
Chapter 6
Option 4
Ta ble 4 . 1
Fig &
Ind #
En g i n e R u n n i n g B e a c o n ( R e fe r t o F i g u r e 4 . 1 )
Part Number
MFR
Code
Description
Qty
4.1
12913029
81381
ENGINE RUNNING BEACON
REF
-1
876-3193-24V
81381
. Beacon, Amber, 24V (DS13)
1
-2
NO NUMBER
COML
. Screw, #6-20 x 5/8"
3
-3
8471-011
81381
. Lens, Amber
1
-4
35958-001
81381
. Gasket, Mounting Pad
1
-5
1683
81381
. Bulb, 24V
1
-6
32779-001
81381
. Gasket, Beacon Mounting
1
Usable
On Code
ITEMS NOT SHOWN
-7
12913140
81381
. Flasher, Super Duty (FL2)
1
-8
155020
81381
. Fuseholder, In-line, 1/4 x 1"
1
-9
311015
81381
. Fuse, 5 Amp (F6)
1
-10
8923907
81381
. Sensor, Pressure, N/O, Closes 5 psi (SE2)
1
-11
NO NUMBER
COML
. Screw, #6-32 x 0.63"
3
-12
NO NUMB ER
COML
. Lockwasher, #6
3
-13
NO NUMBER
COML
. Nut, #6-32
3
CD295
4327
6-4-3
Orig
Chapter 6
Option 4
This Page Intentionally Left Blank
6-4-4
Orig
CD295
4327
Chapter 6
Option 5
Chapter 6, Option 5
Jet Start Mode Timer
5.1
DESCRIPTION
5.1.1
5.2
OPERATION
5.2.1
5.3
This option adds a timer and two indicator lights (red) that illuminate when the
unit has been operated in Jet Start Mode for over seven minutes. There is a keyed
reset switch to reset the lights. There is also a light check function built into the
keyed switch.
When the unit Mode Selector Switch in placed in the Jet Start position, a signal is
sent to Time Delay TD4 thus energizing the coil on TD4. The time delay begins a
seven minute cycle, and if the Mode Selector Switch is left in the Jet Start Mode,
after seven minutes the time delay contacts 2-6 and 1-5 will close. Closure of
contacts 1-5 will energize and illuminate red lights DS14 and DS15. Closure of
contacts 2-6 will latch in the coil of the time delay TD4 keeping the lights illuminated until the keyed reset switch S27 is engaged to removed the power to the
time delay thus reset the time delay to off and removing power to the red lights.
PARTS LIST
5.3.1
CD295
6657
Refer to Table 5.1 for a complete list of component parts.
6-5-1
Rev 3
Chapter 6
Option 5
Table 5.1 Jet Start Timer Light Option
Fig &
Ind #
Part Number
MFR
Code
5.1
Description
Qty
Jet Start Timer Light Option
-1
37TB-4
81381
Terminal Board
1
-2
LE000318
81381
Diode
1
-3
LE000131
81381
Resister
1
-4
70120F
81381
Time Delay
1
-5
CDC00154
81381
Switch, Keyed
1
-6
CDC00401
81381
Contact Block, N.C.
1
-7
CDC00301
81381
Contact Block, N.O.
1
-8
LE000062
81381
Lampholder
2
-9
LE000062
81381
Lens, Red
2
-10
LE000063
81381
Bulb
2
-11
SD000504
81381
Enclosure & Backplate
1
-12
SL000008
81381
Label
1
6-5-2
Rev 3
Usable
On Code
CD295
6657
Chapter 6
Option 6
Chapter 6, Option 6
Engine Warm-Up Circuit
6.1
DESCRIPTION
6.1.1
6.2
OPERATION
6.2.1
6.3
This option adds a thermostat into the engine water jacket that will not allow the
unit to be operated in Jet Start Mode or Air Packs Mode until the engine has
warmed up to 180 degrees F. A green indicator light is located on the unit
exterior above the Control Box to inform the operator when the unit is ready for
use in it's operating modes.
Thermostat (S28) closes when the engine water reaches a temperature of about
180 degrees F. The closure of S28 energizes the coil of relay K22 which closes its
contacts 6-10 and 8-12. Closure of contacts 6 - 10 energizes green light DS16 and
the closure of contacts 8-12 allows electrical signals to be sent to the engine
ECM allowing the engine to operate in the RPM range required for unit
operation.
PARTS LIST
6.3.1
CD295
6657
Refer to Table 6.1 for a complete list of component parts.
6-6-1
Rev 3
Chapter 6
Option 6
Table 6.1 Engine Warm-Up Circuit
Fig &
Ind #
Part Number
MFR
Code
6.1
Description
Qty
Engine Warm-Up Circuit
-1
SE001000
Switch, Temperature
1
-2
RY4S-ULDC24V 81381
Relay
1
-3
125-1192-403
81381
Lens, Lamp, Green
1
-4
43J390
81381
Resister, 390 OHM, 3W
1
-5
125-1310-11-103 81381
Holder, Lamp
1
-6
67785
81381
Bulb, 28V, T-3-1/4
1
-7
SY4S-05
81381
Socket, Relay
1
-8
SY4S-51F1
81381
Spring, Relay Hold Down
1
-9
SL000009
81381
Label, Jet Start Warning
1
-10
SL000010
81381
Label, Jet Start Warning Light
1
6-6-2
Rev 3
Usable
On Code
81381
CD295
6657
Chapter 6
Option 7
Chapter 6, Option 7
Counter and Label - Emergency Stop
7.1
DESCRIPTION
7.1.1
7.2
OPERATION
7.2.1
7.3
This option adds a label adjacent to the Emergency Stop Switch to warn against
using the Emergency Stop Switch for normal shutdown. It also adds a counter in
the Control Box to count the number of times the Emergency Stop Switch has
been utilized. Each time the Emergency Stop Switch is engaged, the Counter
increments up by one count.
Closure of the Emergency Stop Switch S9 energizes relay K9. Counter C1 is
wired in parallel with the coil of K9, therefore each time the Emergency Stop
Switch is utilized, the counter increments up by one count.
PARTS LIST
7.3.1
CD295
6657
Refer to Table 7.1 for a complete list of component parts.
6-7-1
Rev 3
Table 7.1 Counter and Label Emergency Stop Option
Fig &
Ind #
Part Number
MFR
Code
7.1
Description
Qty
Counter % Label Emergency Stop Option
-1
SL000007
81381
Label
1
-2
SE000114
81381
Counter
1
6-7-2
Rev 3
Usable
On Code
CD295
6657
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
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Service Manual
Datum
Seite
21.06.2000
1 von 16
Service Manual
for Oil Free Single Stage Air Compressors
Type CD26S, CD42S and CD72S
in Air Start Units
TUG
GHH-RAND
Part-No.
Part-No.
SP 000 001
401-9-005086
CD26S – R 18
SP 000 002
401-9-005086
CD26S – R 20
SP 000 003
401-9-005090
CD42S – R 9
SP 000 012
401-9-005090
CD42S – R 10
SP 000 004
401-9-005090
CD42S – R 11
SP 000 005
401-9-045450
CD72S – R 6
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Model
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
Contents
1.
General Datas
1.1
Design Features of CD...S Compressor Blocks
2.
Drawings
2.1.1
Installation Drawing CD26S
2.1.2
Assembly Drawing CD26S
2.2.1
Installation Drawing CD42S
2.2.2
Assembly Drawing CD42S
2.3.1
Installation Drawing CD72S
2.3.2
Assembly Drawing CD72S
3.
Operation and Maintenance
4.
Transportation, Storage and Shut down
5.
Recommendation for Oil Types
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Datum
21.06.2000
Seite
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GHH-RAND
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Service Manual
1.1
Datum
21.06.2000
Design Features of CD...S Compressor Blocks
GHHr A ND
Characteristics
•absolutely oil-free compression
•high reliability
•high performance and efficiency
•robust design
•small space requirement
•optimized adaption of compressor speed and motor
speed due to the flanged gear unit
•long life bearings
•effective shaft sealing system
GHHr A ND
Basic configuration of stages
• two meshing rotors
• casing for all rotating parts
• bearings for radial-, axial support of rotors
• shaft seals on each rotor
• timing gear between male & female rotor
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GHH-RAND
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Service Manual
1.1
Datum
21.06.2000
Design Features of CD...S Compressor Blocks
GHHr A ND
Main Parts and their Design
inflow
LP stage
• housing surface-cooled
outflow
Speed increaser
• various gear transmission ratios for different
performance ranges on only one frame size.
• Stage directly flanged to speed increaser
Lube oil tank
• CD9S...CD42S: oiltank flanged to gear box
• CD72S:
no oiltank in scope of supply
Lubrication oil pump
• driven by driving wheel of gear set
• CD9S, CD14S: integrated in gear cover
• CD26S...CD72S: oilpump mounted at gear box
GHHr A ND
Shaft sealings - suction side
oiltank
vent
hole
oil
air
casing
Rotor
shaft
splash ring
oil-retaining
ring
sealing ring
Main purposes:
• no air leakage losses from compression chamber via rotor journals
• no lube oil from bearings to the compression chamber (negative thread)
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GHH-RAND
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Service Manual
2.
Datum
Drawings
Please find the following drawings attached as separate dxf.files:
2.1.1
Installation Drawing CD26S
2.1.2
Assembly Drawing CD26S
2.2.1
Installation Drawing CD42S
2.2.2
Assembly Drawing CD42S
2.3.1
Installation Drawing CD72S
2.3.2
Assembly Drawing CD72S
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GHH-RAND
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Service Manual
3.
Datum
21.06.2000
Operation and Maintenance
Disassembling
Service procedure for changing the oil pump on CD...S Jet Starter
Blocks
•
Please disconnect the pipes for delivery and suction entering in
the rear side of the oil pump (Pos. 1)
•
Please make sure to open the connections with two spanners to
eliminate strains on the pump housing
•
Do not use a hammer for pulling the pump away from the gear
housing (Pos. 2)
Suggestion:
If you move the pump sidewards by hand, or you may use a screwdriver between the flange of the pump and the gear case is sufficient
to take the pump away. (Pos. 3)
Before you take the pump away please put your hand underneath, as
a small coupling may fall out.
This coupling has an inbuilt cross. The cross only fits in one particular
position. However there is no difference if this cross coupling is used
from which ever side.
Assembling
Assembling remounting the connectors for the oil houses the oil pump
should be placed in a vice.
Attention: Please do not span it on the front square flange. (Pos. 4)
The right place to span it is the round side of the pump very near to
the pipe connectors. (Pos. 5)
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Service Manual
Datum
21.06.2000
Insert the cross coupling.
Please check if the pump flange fits to the gear housing (no gap).
If this is the case, use locktide, red colour No. 510.
For the bolts please use locktide No. 241 blue.
Please secure that locktide gets 24 hours hardening time before unit
is put back into operation.
Unit is now ready for start up.
Please find herewith the above mentioned drawing (Point 1 to 5):
4
3
5
1
2
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GHH-RAND
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Service Manual
Datum
21.06.2000
Service Procedure for oil change on CD...S Jet Starter blocks
1.
Please drain the oil shortly after the engine was stopped.
2.
Please remove screw positioned as No. 1.
3.
Please wait three minutes for the oil to drain completely
into the oil sump.
4.
Please remove the plug from the oil sump.
5.
There is no need to open the plug from the gear case as
this oil runs automatically back into the oil sump.
6.
Please disassemble the oil filter with an appropriate tool
(just like on a car).
Filling instructions
1.
Please fit a new oil filter.
2.
Make sure that the gasket of the oil filter has a small oil
film and the surfice of the oil sump is dry and clean.
3.
Please close the venting hole by using the plug as per
Position No. 1 in the following (next page) drawing.
4.
Please fill in only officially recommended oils as indicated
in our oil recommendation list from GHH-RAND.
5.
Please fill the oil till three quarters of the oil glass is filled.
Note: Oil must be changed at least once a year even so
the unit may not have been used for many running hours.
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Service Manual
Datum
21.06.2000
GHHr A N D
Oil-free Single Stage Screw Compressor
1
VI/WS 15.6.1999
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CD...S
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Service Manual
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Seite
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GUIDELINE No. 6510.02
Mesh width of oil filters for operation of anti-friciton bearings
Dirt particles in the lube oil especially extremely hard (> 700 HV) and sufficiently big (> lubricating
gap) particles can have a decisive influence on the wear and thus the life of a bearing and should
therefore be filtered out of the lubricant.
The manufacturers of anti-friction bearings prescribe the use of oil filters with a mesh width of 25 µm
for bearing inner diameters of 30-60 mm and < 10 µm for bearing inner diameters of < 30 mm. However, this nominal mesh width does not necessarily imply a good separating quality of the filter itself.
The retention rate according to DIN-ISO 4572 gives a much better description of the filter. It virtually
describes the filter efficiency for a certain particle size. For scavenging and test runs, the
manufacturers of anti-friction bearings recommend the use of filters with a retention rate of β6 = 100.
This value indicates that only 1 out of 100 6 µm particles upstream of the filter pass through it while 99
particles are retained. The degree of separation of the filter for this particle size thus is 99.0%. The
biggest particles which still pass through this filter have a size of approx. 24 µm.
Considering that the thickness of the lubricating film between raceway and rollbody dependent on κ
(= operating viscosity/reference viscosity) lies between 0.2 and 1.0 µm, it becomes clear that there is
no absolute protection of a bearing against contamination at a reasonable i.e. economical expense.
However, filtering of the oil should always be as fine as possible even under economical aspects in
order to achieve the longest bearing life possible.
In view of the above, a filter with a retention rate of β6 = 100 is an acceptable compromise.
The retention rate of e.g. the easy-change filter cartridge W920/6 used for the single-stage CD blocks
is by far worse, that is β25 = 75. The manufacturers of anti-friction bearings, however, accept this
when filtered oil (β6 = 100) is used for initial filling and also for filling up later on.
This recommendation of a mesh width of oil filters for operation of anti-friction bearings requires that
the anti-frictions are protected against contamination right from the beginning. This is achieved by
taking the following steps:
-
Careful deburring of housing and single components,
-
cleaning of all components prior to the assembly,
-
keeping the assembly workplace clean,
-
dustproof coverage of partly assembled subassemblies
and finished machines
-
scavenging of the lubricating system with filtered oil (β6 = 100)
while slowly turning the rotating parts prior to the test run,
-
careful plugging of all openings after the test run,
-
filtering of the preservation oil.
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GHH-RAND
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Org.-Einheit, Verfasser, Telefon
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Service Manual
Datum
Seite
21.06.2000
11 von 16
GUIDELINE No. 6510.01
Permissible dust load on dry-running screw compressors
This guideline refers to the screw compressor and not to the requirements of possible users.
dry
compression
with liquid
flushing
max. concentration mg/m3
20
300
max. particle size µm
10
10
Through flushing or bringing-in appropriate solvents (if necessary together with a spinning
device), make sure that the dusts do not built up to a sticking deposit of which bigger parts may
come off suddenly and enter the compressor.
Special dust characteristics (e.g. abrasive or corrosive) must be considered when choosing the
rotor and housing material.
GRS 0006/1/2 • X:\PDS\TechPub\DOCS\TMD 150-180-250\Vendor\GHH-RAND Compressor Manual for S&S TUG.doc
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
4.
Datum
21.06.2000
Transportation, Storage and Shutdown instructions
Should the compressor block be shut down for an extended
period, make sure that it is protected from corrosion, in particular
when installed outdoors or in cold rooms. The type and extent of
such protective measures depend on the climatic conditions at the
place of installation, and on the length of the downtime.
Should the downtime be less than one month, no special
preservation measures will have to be adopted as a rule. The oil
film in the bearings and in the gear unit can be renewed through
about 10 minutes of trial operation per week.
If the compressor block is shut down for more than 1 month, all the
lube oil should be completely drained and replaced with preserving
oil. Short-time operation of between 5 and 10 minutes will coat the
bearings and gears with a protective film of preserving oil. All non
painted surfices have to be protected with anti corrosion film.
Should the compressor package be installed indoors and be
potentially affected by heavy vibrations or impacts through other
machinery, the bearings are at risk of beeing damaged. This risk
can be reduced by rotating the motor, gear unit and compressor
stages once per week.
Transportation of the compressor block:
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Seite
12 von 16
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
Datum
Seite
21.06.2000
To lift, use ropes as shown:
G HHr A N D
Oil-free Single Stage Screw Compressor
VI /WS 15.6.1 999
Make sure, that all pipes, the oil pump and the oil tank are free
from any load.
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CD...S
13 von 16
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
5.
Datum
21.06.2000
Recommendation for Oil Types
Type of Lubricants
We wish to draw the attention of our clients to the fact that proper
lubrication of our high-tech machines is a major precondition for their
reliable operation. Proper use of the most suitable lubricants helps
achieve the best performance and avoid operational trouble.
For this reason we recommend that suitable oils having the following
properties be used: non-ageing, anti-corrosive, low foaming tendency.
The following types of oil have proved satisfactory in the past:
-
Turbine oils L-TD according to DIN 51515, or
Hydraulic oils HLP according to DIN 51524, part 2.
We are not in a position to test the suitability of the various types of
lubricants available on the market since this involves long-term testing.
For this reason we cannot release any individual lubricant either.
However, all lubricants meeting the requirements defined in these
recommendations are generally admissible provided their use does not
give rise to any adverse conditions.
Selection of Lubricants
Viscosity is the most important criterion of a lubricant for our
compressors. It must be at least 20 mm2/s (cSt) at the inlet to the
bearings or to the theet mesh of the drive and timing gears.In selecting
the lubricant, account must be taken of the temperatures involved since
the oil viscosity is highly dependent on the respective temperature.
Normally an oil inlet temperature of 50 °C at the lube points is envisaged
on water-cooled oil coolers used generally on compressor trains. When,
however, air-cooled oil coolers are used, it is often possible to attain
higher oil temperatures. For this reason we recommend a selection of
basic viscosities as per the following table:
Oil inlet temp.
°C
up to 50
up to 60
up to 70
up to 80
VG 32
VG 46
VG 68
VG 100
mm²/s 28.8-35.2 41.4-50.6 61.2-74.8
90-110
ISO viscosity class
Viscosity
at 40 °C
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Seite
14 von 16
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
Datum
21.06.2000
In order to prevent wear on anti-friction bearings and drive and
timing gears as far as possible, it is recommended that only oils
containing wear-reducing additives – designed to at least ensure
the FZG load stage 9 – be used.
Admixtures, Contaminations
-
Water
Water in oil can cause lubricant break as a result of which
bearings can suffer serious damage. For this reason care must
always be exercised to see that no water finds access into the
oil tank.
-
Dirt
Abrasive contaminations such as, for example, grinding or
blasting residues, generally cause heavy bearing damage. It is
therefore necessary that the lubricant is filtered in the most
suitable manner (recommended filter fineness ß25 = 75
according to ISO 4572).
When using oil filters with an internal bypass it must further be
ensured that this is never activated. Particular attention has to
be paid to the fact that the bypass s not even opened in the
event of a machine cold start if the pressure loss rises due to
increased viscosity.
Such an effect is particularly dangerous as in such a case any
previously filtered-out residues would be washed into the
bearings at a great concentration together with the oil.
Since even fresh oil frequently contains large amounts of
contamination, it is recommended that the oil be filtered when
filling the oil tank (recommended filter fineness ß6 = 100
according to ISO 4572).
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Seite
15 von 16
GHH-RAND
Kennwort, Projekt-, Auftrags-Nr.
Org.-Einheit, Verfasser, Telefon
TUG Technologies Corp.
VI/B. Loibl, Tel.-4048
Service Manual
Datum
21.06.2000
Cold Start
If the machines are operated in areas where the oil can cool down
substantially during long shutdowns, then the oil must be heated
with an oil heater to make it flow freely before re-starting the
machine.
A starting oil viscosity of 1000 mm2/s is required for our CD series.
Please refer to the VT diagrams of mineral oil companies to
ascertain at what temperature this viscosity is attained.
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Seite
16 von 16
TMD 150/180 AIR START UNITS
GHH-RAND GEAR SET SPARE PARTS LIST CD26S
ITEM
NO.
1
2
6
7
8
9
10
11
12
13
18
20
21
22
25
27
28
33
34
42
43
49
53
58
63
64
79
80
84
85
86
PART NUMBER
DESCRIPTION
QUANTITY
401-4-001883
Gear Set, CD26S
Ref.
83900717
83900773
29277000
29517000
83900748
83900714
83900753
21012000
27022000
83900749
37601764
82946000
79465000
82805000
82947000
65454000
83900719
83901537
83901540
25707000
83900527
83901005
21020000
83900853
37600764
83900022
83900477
83900479
83900361
83902557
83900359
. Casing, Gear
. Cover, Gear
. Bearing, Ball, Grooved, DIN 625
. Bearing, Roller, Cylindrical, DIN 5412
. Cover
. Race, Bearing with Left Hand Twist
. Ring, Shaft Sealing, Radial
. Bolt, Cylinder, DIN912
. Key, DIN 6885
. Ring, Spacer
. Pump, Oil
. Element, Coupler
. Cover
. Nut, Lock
. Driver
. O-Ring
. Tank, Oil
. Tube, Oil Suction
. Pipe, Oil Suction
. Ring, Retaining, DIN 472
. Valve, Oil Relief
. Return, Oil
. Screw, Hexagon Head, DIN 931
. Sightglass, Oil Level
. Nipple, Hexagon
. Cartridge, Filter
. Fitting, Tube
. Fitting, Tube
. Piping
. Piping
. Piping
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
2
4
1
1
1
TMD 150/180 AIR START UNITS
GHH-RAND GEAR SET SPARE PARTS LIST CD26S
ITEM
NO.
PART NUMBER
DESCRIPTION
QUANTITY
401-4-001883
Gear Set, CD26S
Ref.
83900725
83900363
Kit, Driver, RS12
. Gear, Driving, with Shaft, 12
. Pinion, 12 z = 38
1
1
83900726
83900365
Kit, Driver, RS13
. Gear, Driving, with Shaft, 13
. Pinion, 13 z = 37
1
1
3
5
83900727
83900367
Kit, Driver RS14
. Gear, Driving, with Shaft, 14
. Pinion, 14 z = 34
1
1
3
5
83900728
83900369
Kit, Driver, RS15
. Gear, Driving, with Shaft, 15
. Pinion, 15 z = 31
1
1
3
5
83900729
83900371
Kit, Driver, RS16
. Gear, Driving, with Shaft, 16
. Pinion, 16 z = 29
1
1
3
5
83900730
83900373
Kit, Driver, RS17
. Gear, Driving, with Shaft, 17
. Pinion, 17 z = 27
1
1
3
5
83900731
83900375
Kit, Driver, RS18
. Gear, Driving, with Shaft, 18
. Pinion, 18 z = 25
1
1
3
5
83900732
83900377
Kit, Driver, RS19
. Gear, Driving, with Shaft, 19
, Pinion, 19 z = 24
1
1
83900733
83900379
Kit, Driver, RS20
. Gear, Driver, with Shaft 20
. Pinion, 20 z = 23
1
1
3
5
3
5
3
5
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TMD 250 AIR START UNIT
GHH-RAND GEAR SET SPARE PARTS LIST CD42S
ITEM
NO.
1
2
6
7
8
9
10
12
13
18
20
22
25
26
27
28
33
34
42
43
49
50
53
55
58
63
64
79
80
84
85
86
PART NUMBER
DESCRIPTION
QUANTITY
401-4-001904
Gear Set, CD42S
Ref.
83900721
83900774
29252000
29450000
83900755
83900716
83900757
27029000
83900749
37601764
82946000
82810000
82947000
20347002
65457000
83900723
83901538
83901540
25707000
83900527
83901539
37600779
20318002
20340002
83900853
37600764
83900022
83900477
83900479
83900482
83900481
83900480
. Casing, Gear
. Cover, Gear
. Bearing, Ball, Grooved, DIN 625
. Bearing, Roller, Cylindrical, DIN 5412
. Cover
. Race, Bearing with Left Hand Twist
. Ring, Shaft Sealing, Radial
. Key, DIN 6885
. Ring, Spacer
. Pump, Oil
. Element, Coupler
. Nut, Lock
. Driver
. Screw, Hexagon Head, DIN 933
. O-Ring
. Tank, Oil
. Tube, Oil Suction
. Pipe, Oil Suction
. Ring, Retaining, DIN 472
. Valve, Oil Relief
. Return, Oil
. Sealing
. Screw, Hexagon Head, DIN 933
. Screw, Hexagon Head, DIN 933
. Sightglass, Oil Level
. Nipple, Hexagon
. Cartridge, Filter
. Fitting, Tube
. Fitting, Tube
. Piping
. Piping
. Piping
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
4
2
1
1
1
2
4
1
1
1
TMD 250 AIR START UNIT
GHH-RAND GEAR SET SPARE PARTS LIST CD42S
ITEM
NO.
PART NUMBER
DESCRIPTION
QUANTITY
401-4-001904
Gear Set, CD42S
Ref.
83900734
83900735
Kit, Driver, RS4
. Gear, Driving, with Shaft, 4
. Pinion, 4 z = 43
1
1
83900736
83900737
Kit, Driver, RS5
. Gear, Driving, with Shaft, 5
. Pinion, 5 z = 40
1
1
3
5
83900738
83900739
Kit, Driver RS6
. Gear, Driving, with Shaft, 6
. Pinion, 6 z = 37
1
1
3
5
83900740
83900741
Kit, Driver, RS7
. Gear, Driving, with Shaft, 7
. Pinion, 7 z = 35
1
1
3
5
83900742
83900743
Kit, Driver, RS8
. Gear, Driving, with Shaft, 8
. Pinion, 8 z = 34
1
1
3
5
83900744
83900745
Kit, Driver, RS9
. Gear, Driving, with Shaft, 9
. Pinion, 9 z = 32
1
1
3
5
83900746
83900747
Kit, Driver, RS10
. Gear, Driving, with Shaft, 10
. Pinion, 10 z = 29
1
1
3
5
3
5
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for
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oil
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MB
DETROIT
DIESEL
Series 60
Engine Operator's Guide
@
CALIFORNIA
Proposition
65 Warning
Diesel Engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm,
To the Operator
This guide contains instructions on the
safe operation and preventive maintenance of your Detroit Diesel Series 60
engine used in vehicle, stationary,
construction/industrial, agricultural, or fire
fighting
apparatus
applications,
Maintenance
instructions
cover routine
engine services such as lube oil and fil
ter changes in enough detail to permit
self-servicing, if desired,
The operator should become familiar
with the contents of this guide before
operating the engine or carrying out
maintenance procedures,
Power driven equipment is only as
safe as the person operating the con
trois. You are urged, as the operator of
this diesel engine, to keep fingers and
clothing away from the revolving belts,
drive shafts, etc. on the engine instal[a
tion.
Throughout this guide CAUTIONS
regarding
personal
safety
and
NOTICES
regarding
engine performance or service life will appear. To
avoid personal injury and ensure long
engine service life, always heed these
instructions.
Whenever possible, it will benefit you
to rery on an authorized Detroit Diesel
service outlet for all your service needs
from maintenance
to major parts
replacement. Authorized service outlets worldwide
stock factory original
parts and have the specialized equip
ment and experienced,
trained person
nel to provide
prompt
preventive
maintenance
and skilled engine
repairs.
The information and specifications
in
this publication are based on the infermation in effect at the time of approval
for printing.
Contact
an authorized
Detroit Diesel service outlet for information on the latest revision.The right
is reserved to make changes at any
time without obligation.
NOTICE:
Coolant must be inhibited with the recommended SCA's (supplemental coolant additives) listed in the "How to Select Coolant" section of this engine operator's guide. In
addition, the engine can be equipped with a coolant filter/inhibiter system as an
installed option or as an affer-saJe item. Failure to check and maintain SCA levels at
required concentrations
will result in severe damage (corrosion) to the engine ooolin!
system and related components.
WARRANTY
1
The applicable
engine warranty is contained
in the booklet entitled "Warranty|
Information
for Series 60 Engines," available from authorized
Detroit Diesel service
outlets,
r
j
Keep this Operators Guide with the engine installation at all times. It contains important operating, maintenance, and safety instructions.
Remove
from its backing
the peel*off sticker below
and affix to a convenient
location.
DETROIT DIESEL CUSTOMER ASSISTANCE
U.S. AND CANADA 1-800-445-1980
[f you require road service for any reason in the U.S. or Canada, you may
call the 1_00-445-1980
Customer Assistance phone number. An operator
will assist you in determining
what type of service is required. Not all
problems are engine related and not all problems are covered by engine or
vehicle warranties. YOU MAY BE RESPONSIBLE FOR REPAIR EXPENSES.
Before calling Customer Assistance, please do the following:
• Check coolant level.
•
Check fuel level.
•
Check DDEC fuses.
•
Check for fuel leaks.
•
Make sure manual fuel shutoff vaJve (if installed) on secondary
fuel filter adaptor is open,
Check e]] level on the dipstick.
•
• Check diagnostic codes.
If you call, have the following informal_on available:
• Engineserial number:
• Truck make _a3dmode]
•
•
Odometer mileage
Truck owner or company name
*Write your engine serial number here.
Table
of Contents
Subject
CAUTION
SUMMARY
.........................................................................................
ENGINE MODEL AND SERIAL NUMBER
DESIGNATION
................................
Option
and Certification
Labels ...........................................................................
Page
ii
1-2
1
OPERATING
INSTRUCTIONS
.........................................................................
Preparations
for Starting
the Engine the First T_me .............................................
Starting
the Engine
.............................................................................................
Running
the Engine
............................................................................................
Stopping
the Engine
...........................................................................................
Emergency
Jump Starting
..................................................................................
3-8
DDEC II OPTIONS
.........................................................................................
DDEC Ill/IV OPTIONS ..................................................................................
DDEC Ill/IV ENGINE DRIVING TIPS .............................................................
8-14
15-21
22-23
ENGINE
SYSTEMS
ENGINE
MAINTENANCE
LUBRICATION
3
5
6
7
7
..........................................................................................
SCHEDULES
AND PREVENTIVE
24
.......................................................
MAINTENANCE
INTERVALS
25-27
.................
28-40
"HOW TO" SECTION
..................................................................................
How to Select Lubricating
Oil ......................................................................
When to Change
Oil ....................................................................................
How to Replace
the Lube Oil Filters ............................................................
How to Select
Fuel Oil .................................................................................
How to Replace
the Fuel Filters ...................................................................
Engine Out of Fuel--How
to Restart
...........................................................
How to Select Coolant
................................................................................
How to Drain and Flush the Cooling
System .....................................................
When to Service
the Dry Type Air Cleaner
........................................................
40-63
40-41
41-42
42-43
43-45
45-49
49-50
50-62
62
63
BASIC
64-67
TROUBLESHOOTING
ENGINE
STORAGE
SERVICE
PUBLICATIONS
CUSTOMER
LIMITED
.....................................................................................
ASSISTANCE
NEW
SPECIFICATIONS
......................................................................
ENGINE
68-72
................................................................................
.........................................................................
WARRANTY
..........................................................
.......................................................................................
73
74-75
76-90
g1-94
CAUTION SUMMARY
A
CAUTION:
The following
cautions
must be
observed by the operator of the
vehicle in which this engine is
installed and/or by those performing
basic engine preventive maintenance.
Failure to read and heed
these cautions and exercise reasonable care for personal safety and
The operator of a DDEC-equipped
vehicle must not attempt to use or
read a diagnostic data reader of
any kind while the unit is operating. Doing so can result in loss of
vehicle control, which may cause
vehicle damage and may result in
personal injury.
the safety of others when operaUng
the vehicle or performing
basic
engine preventive maintenance may
result in personal injury and engine
and/or vehicle damage,
When engine or electronics system diagnosis is required on a
DDEC-equipped vehicle, this must
be done by a person other than
the operator. The operator must
1. Observe the following cautions
when operating the engine:
maintain control of the moving
vehicle while the assistant performs _ diagnosis.
A
CAUTION:
CAUTION:
The operator of a DDEC-ecluipped
engine should know the extent of
the wamkig system on his vehicle
in order to bring it to a safe stop in
the event of an engine malfunct_on. A description of the warning
system and detailed instructions
regarding its operation should be
obtained from the owner, the seller, or the manufacturer
of the
vehicle. This information may also
be obtained from any authorized
To avoid the possibility of vehicle
damage and/or personal injury,
Detroit Diesel does not recommend using cruise control under
these conditions:
"When it is not possible to keep
the vehicle st a constant speed
(on winding roads, in heavy
traffic, in laraffic that varies in
speed, etc.).
Del_oit Diesel service outlet.
To be confronted
with a power
down/shutdown situation without
knowing how the DDEC system
works could cause the vehicle to
stop in an unsafe location, posing
the possibility of damage to the
vehicle and a threat to the safety
of the operator.
• On slippery roads (wet paveI
J
L
ment, ice or snow-covered
roads, loose gravel, etc.).
2. Observe the following cautions
when performing basic preventive
maintenance on the engine:
_
CAUTION:
_e rotaUng fan, pulleys, and belts
of an operating engine may pose
certain hazards when servicing the
engine. To avoid possible personal
injury, follow these precautions:
CAUTION:
Engine exhaust may be harmful to
your health if inhaled. Please note
this caution and remember:.
• Shut down the engine before
performing
basic preven'dve
maintenance.
• Always start and operate the
engine in a well ventilated area.
• If this is not possible or practical
(as during transmission fluid
level check), keep hands, cloth-
• If in an enclosed area, vent the
exhaust to the outside,
• Do net modify or tamper with
ing, and tools away from the
fan, pulleys, and belts while the
engine is running.
the exhaust system,
• Avoid wearing lease clothing or
CAUTION:
jewelry
can
caught
in
the fan, which
pulleys,
or get
belts.
DO not
place tools where they can fail
into the fan system, becoming
projecitles which may cause
personal injury or property
damage.
When working near the engine,
always remove loose items of
clothing or jewelry that could get
caught in a moving part of the
engine and cause personal injury,
Safety glasses and hearing
tectien must also be worn.
pro-
• Those with long hair should tie
hair back or contain it in a hat to
prevent po6sibte entanglement
with the fan, pulleys, or belts.
CAU'RON:
• Be especially cautious when
working on vehicles equipped
_
electric fans, since these
fans may start without warning
to
meet engine cooling
demands.
To avoid personal injury (burns,
eye injury) from the hot oil, do not
operate the engine with rocker
covers removed for any reason,
_
CAUTION:
Personal injury and/or property
damage may result fl_m fire due
to the leakage of flammable fluids
such as fuel or lubricating
oil.
Contain and eliminate all leaks as
they occur.
iii
3. Observe the following
cautions
when using compressed air.
CAUTION:
Personal injury and/or engine
damage may result from direct,
physical contact with the vibration
damper of an operating engine.
This may occur if tools or other
objects strike or become lodged
behind the damper during operation. An object coming in contact
with the damper of an operating
engine may be thrown off with
force, becoming a dangerous projectile which COuld cause personal
injury, property damage, or both.
A
m=
_
CAUTION:
To prevent
possible
personal
injury when using compressed air,
wear adequate
eye protection
(face plate or safety glasses) and
do not exceed 40 psi (276 kPa) air
_ressura.
AlL
_
CAUTION:
Do not apply compressed air to
any part of the body or clothing.
CAUTION:
face or body maydirected
Compressedair
cause eye
at the
or
hearing
injury or other serious
physical injury.
The rotabng turbocharger impelle
wheel may pose a hazard when fl_
air inlet piping is removed. To avoi(
possible personal injury when al
engine must be operated with the
air inlet piping removed,
do not
start or run the engine without first
installing the _boc_rger
air inlet
shield (J 26554-A).
4. Observe the following
caution
when using starting aids:
4_
_
CAUTION:
Starting fluid used in capsules is
highly flammable, toxic, and possesses sleep-inducing properties.
Do not inhale vapors from starting
fluid capsules,
CAUTION:
Improper use of caustic chemicals
may result in personal injury. If
cleaning of an engine component
should become necessary prior to
replacement,
follow the solvent
manufacturer's
usage, handling,
and disposal
instructions
and
5. Observe the following
cautions
when jump starting
an engine,
charging
a battery, or working
with the vehicle elent#cal system:
observe all manufacturer cautions.
A
CAUTION:
To avoid possible personal injury
and/or engine damage from accidental eng/ne start-t_o, always d/sconnect
the
battery
before
servicing the electrical system.
iv
CAUTION:
_
CAUTION:
Reversing battery polarity may
result in personal injury caused by
the sudden discharge
of electrolyte from the battery vents
and/or the sudden rupture of the
battery case by explosion of inter-
When the temperature
of diesel
fuel is elevated, as occurs when
the fuel is circulated through an
operating engine, it may pose the
following hazards which should be
guarded against:
nal hydrogen gas. Always establish the correct polarity before
connecting cables to the battery
or battery cireuit,
• Heated liquid fuel may cause
scalding if allowed to come in
contact with the skin. Heated
diesel fuel can form combustible vapor mixtures in the
CAUTION:
Do not touch battery terminals,
alternator
terminals,
or wiring
cables while the engine is operating. Severe electrical shock, which
may lead to personal injury may
result from improper shielding of
electrical components,
areaaroundthefuelsource.
• Whenever possible, it is recommended that the engine and fuel
be given an opportunity to cool
down to ambient temperature
before performing service operations which could result in
spillage of fuel from the engine
or vehicle fuel system.
Observe the following cautions
when fueling the vehicle, replacing fuel filters or working with the
engine fuel system:
• When this is not possible, protective clothing and safety gear
(insulated gloves, apron, face
shield) should be worn when
performing these operations.
• Engine
CAUTION:
The addition of gasoline to diesel
fuel will create a serious fire hazard. Do not mix gasoline
dieselfuel,
with
or vehicle fuel system
service
performedoperationsshouldbe
in a well ventilated
area
that is kept free of
bystanders.
• Keep open flames, sparks, electrical resistance heating elements,
or other
potential
ignition sources away and do
not smoke during vehicle refueling or other service operations
which could result in the escape
of liquid or vaporized diesel fuel.
• Mop up or absorb spilled fuel
immediately to avoid danger of
possible slip and fall injury.
Bk
7. Observe the following cautions
when servicing the cooling
_J_
system:
_]_
CAU'nON:
"rile rotaffilg turbocharger impeller
wheel may poss a h_T_rd when the
CAUTION:
air inlet piping is removed. To avoid
possible personal injury when an
engine must be operated with the
air inlet piping removed, do not
start or run the engine without ;',_L
installing the turbocharger air inlet
shield (J 26554-A).
To avoid personal injury, do not
remove the pl_osure control cap
from the radiator or attempt to
drain the coolant until the engine
has cooled. Once the engine has
cooled, use extreme caution when
removing the Cap. The Sudden
release of pressure from a heated
cooling system can result in a loss
of coolant and possible personal
injury (scalding, eye injury, etc.)
fn)m the hot liquid.
9. Observe the following
cautions
when replacing the engine lubHcating oiland filtem:
A
CAUIX)_
Whentheb_membleofenojnek_dCAUTION:
the oil is circulated through mt operat-
Mop u_ or absorb spi---_lled
coolant !
immediately
to avoid danger of ]
possible slip and tall injury,
j
mg engkle, it may pose the foaowing
hazards which should be guarded
againsl:
• Heated oil may cause scalding if
alowed to seine in centact wif_ the
sldR
caingoiliselevated,
asoccurswhen
8. Observe the following cautions
when working on the engine air
intake system:
A
lP.oleclJve dolhlog and _;_t.y gear
_su_ed g_ve_ apro_ face sh_d)
should be worn whan _
hot
CAUTION:
lubdcatng oi.
1Lubrica'dng oil should be drained
and replaced in a well ventilated
area _
is kept frse of by_, xter_
To avoid personal injury (burns
from the turbocharger or engine)
or turbocharger
damage, do not
remove, attach, or tighten turbocharger air intake ducting while
the engine is opereUng or operate
the engine with the ducting
1Keep open flames, sparks,_
resistance heating elements, or
other potential ignition sources
away and do not smoke when
removed,
drak-ang
or replacingIshdcatJng
oU.
_]_
CAUTION:
Mop up or absorb spilled lubdcating oil immediately to avoid danger of pose b e sl p and ta I injury.
vi
ENGINE MODEL AND
SERIAL NUMBER
with any order for parts, the engine
model and serial number must be given.
If a type number is shown on the option
label covering the equipment required,
this number should also be included on
the parts order.
Transmissions
and power take-offs
generally carry their own name plates.
The model and serial number informa-
DESIGNATION
The engine serial number and model
number are stamped on the cylinder
block in the following location (as viewed
from the flywheel end):
Left side just below the intake manifold and above the cast-in Detroit
Diesel logo. See Figure 1.
Option
tion on these plates is useful when
ordering parts for these assemblies.
Certification
Labels
Computerized engine option labels are
attached
to the valve rocker cover,
These labels contain the engine sedat
number
and model number
and, in
addition,
list any optional equipment
used on the engine. Labels also include
required tune-up information (injection
timing, valve lash, max. no-load RPM,
etc.). See Figure 2.
Labels
If required,
a certification
label is
attached to the valve rocker cover. This
label certifies that the engine conforms
to federal and oentain state emissions
regulations for its particular application. It
also gives the operating
conditions
under which certification was made.
0
Figure 1. Locationof Engine Serialand Model Numbers
1
D262 FUELPUMP
0409 INJECT0R
0638 OILFILTER
0444 PWRSTRADAP
0358 THERMOSTAT
0893 VENTSYSTEM
0464 WATBYPASS
UNITOGRO
SD
EER 14B07
1404 AIRCOM9
0178 G/SCOVER
0693 DONNROS/PgTI6
0566 DYLBLOCK
0260 ENGLIFTORKT
0715 EXHMANIFOLD
1758 FANMOUNTS
0840 FUELF]LTEa
UNITS6RO
$.0.
2261 SENMOUNT
0688 INJDONTELEC
DETROIT
1405 alL COOLER
0594 OILDINT
0919 OILPAN
0169 OILFILSHPGONL
0445 PWSSTRADAPT
0583 ROCKER
COVER
1743 TURBOCBAROER 0650 VALVEMECH
1072 VENTSYSTEM
0161 VIB DAMPER
0459 WATERCONN
0306 WAFERPUMP
MODEL606
OIES|L
,.,.,._._mw
usa
SPED
0438 ADGDRIVE
THISENGINEWAS
0028 AIRINTKMFLD
TEGTEDAT430SF
0387 D/SPULLEY
AT2100 RPM
D131 CRANKSHAFT
II_J.RETTINOSI.0MM
1448 DIPSTICK
VALVELASH
0765 ENGINEMOUNTS EXHAUST.660
MM
0071 F/WHOUSING
INTAKE
.203MM
1260 FLYWHEEL
MAXRPMNL2225
2126 FUELLINES
STDCAMTIMING
MODEL606
SPED
D_rRorl
" O|mSlEL
O_-_rROIT
DIESEL
,.,..,,_4_now
u s_
D_TROIT
DIESEL
co_m_,_.,
u s_
THISENGINEISNOTCERTIFIED
FORUSEtN ANURBANBUSAS
DEFINED
AT40 CFR86.0932. gALEOFTHISENGINE
FOR
USEIN ANURBANBUSISA VIOLATION
OFFEDERAL
LAWUNDER
THECLEAN
AIRACT.
THISENGINE
LSCERTIFIED
TO OPERATE
ON
LOWSULEURDIESELFUEL.
UNIT06RO
IMPORTANT
ENGINEINFORMATION
THISENGINE
CONFORMS
TO U.S.EPAANDDALIEORNIA
REGULATfONS
APPLICABLE
TO 1999MODELYEARNEWHEAVYDUTY
DIESELCYCLE
ENGINESTHISENGINE
HASA PRIMARYINTENDED
SERVICE
APPLICATION
ASA HEAVYHEAVYDUTYENGINE.
FUELRATEATADV.HP250.6 MM3/STRSKE
ADV.HP500AT2100 RPM
INITIALINJECTION
TIMING14 DECBTG
DIgP.12] LITERS
ENGINEFAMILYXDDXN12.7EGL
MIN.IDLE600 RPM
MODELSERIES
60, 12.7L
MFG.DATEDEC1998
UNIT06RO
CONFORMS
TOAUSTRALIAN
DESIGN
RULE30
1999
50g
Figure 2. Typical
Engine
Option
and Certification
labels
2
OPERATING
3. Entrapped air must be purged after
fittingthe ceeling system. To do this,
allow the engine to warm*up with
INSTRUCTIONS
PreparatlJons
for StarliNg
the pressure cap off. With the transmission in neutral, increase engine
speed above t ,000 BPM and add
coolant as required.
the Engine
the First Time
When prepenng to start a new or newly
overhauled engine or an engine which
has been in storage, perform all of the
operations listed below. Failure to follow
these instructions may result in serious
engine damage. Before a routine start,
see "Daily" checks in the Engine
Malnteqancechar_ (pages25-27).
4. Check to make sure the front of the
radiator and air-to-air charge cooler
(if equipped) are unblooked and free
of debris.
CAUTION:
been
in storage
for six
months
or more,
may be
insufficient
when
the engine
is
startedfor thefirst time. Insufficientlubrication at start-up can cause serious
damageto enginecomponents.
To insure an immediateflow of oil to
all bearing surfacesat initialenginestartup, the enginelubricationsystemshould
be charged with a commercially avaiF
able pressure pre-lubricator. If this is
impractical,
rocker covers should be
removedand clean lubricatingoil should
be poured over the rocker arms. The oil
should be the same weight and viscosity as that used in the crankcase. After
pre-lubricating, add additional oil to
bring the level to the proper mark on the
dipstick. See F_jure3. Referto How to
Select Lubricating Oil (page 41) for
lubricantrecommendation.
A
Lubricating System Checks
The lubricating oil film on the rotating
parts and bearings of a new or newly
overhauled engine, or one which has
When working near the engine,
always remove loose items of
clothing or jewelry that could get
caught in a moving part of the
engine and cause personal injury,
Safety glasses and hearing protection must also be wom.
Cooling System Checks
1. Make sure all the drain cocks in the
cooling system are installed (drain
cooks are oftenremovedfor shipping)
and are dosed tightly,
2. Removethe radiatorpressure control
cap and fillwith genuineDetroitDiesel
Power Cool antifreezeor an equivalent quality ethyleneglycol or propylane glyeel-beeeant_esze soMticn in
the required
concentration.
In
extremely hot environments, clean,
soft, properly inhibited water may
be used in the summer. Keep the
coolant level at the bottom of the filler
neck to allow for expansion of the
coolant. For more detailed coolant
recommendations, refer to How to
Select Coolant (page52).
Extended Stora(_ An ePr_icein storage for an extended period of time (over
winter, for example) may accumulate
water in the oil pan through normal condessationof moisture(alwayspresentin
the air) on the cold internal surfaces of
the engine. Lube oil diluted by water
cannot provide adequate bearing protection at engine startup. For this rea-
3
son, Detroit Diesel recommends replacing the engine lube oil and filter(s) after
extended storage,
NOTICE:
Failureto eliminatewater-diluted lube I
oil may lead to serious engine damage I
atstartup.
J
Make sure the transmiesionis filledto
the proper level with the fluid recommendedby the gear manufacturer,
f
Figure3.CheckLubeOilLevel
BeforeStarting
R_el _stem Checks
Fillthe tank with the recommendedfuel.
Kee#ng tanks_1 _
water conds_
s_ion and helps keep fuel cool, which is
important to engine performance. Full
tanks also reduce the chances for microbe
(black slime) growth. Refer to How to
Select Fuel Oil (page44) for fuel recornmandatY:_.
Makesurethefuelsupplyshutoffvalve('rfused)isopen.
To insureprompt stariir_and evanrunnbg,thefuelsy_emrrtstpe_:_hledifaYhas
enteredthefuelsystem.Primingis doneby
cor_
am_ualoreleetltcF_,tr_gpurt_
to _e seccedatyfuelfilter.AuS-oizedDetroit
Diss_se'Tceoul]etsareprepedyequppedto
peformthisse'voa
Priming is not normally necessary if the
filter elements are filled with fuel when
installed and the marfltolds are not drained
offud.
NOTICIB
Prolonged use of the _
motor and
er_qe fueli:x_ to ic#methefuelsyste_
can result in damage to tie starter, fuel
pump, and irfjectors, and cause erraf_
engre gee_,:tl_n
dueto the amountofair
h the [r_s and flters from file s_4oplyta_
to the_
heaJ.
Engheseqd#ped with stardngdevk:es
reservoirs should always be primed
before inlt_ star_p. Other,
re_e
pressure can be _ed
and irfjeotors
may be c_r_ged f_m leck of lu_
dependent
cooling. on compressed air or gas
Ullc_r no ¢EBx#umstances
shoulda
_l_l;._g_ _
as ether be.usedft¢)
runthe ewzj_eunB flaefuel syst_mis
prmed. _or
damagewa occurif
Uis me_od is used.Tnehe_ gsea_ed
by the externalfuelsourcewillcausethe
iiector ltgeto be damagedwhanthefue
cools them. The _
and _
can
be scored from _wilhoutlub_.
If the engine is equipped with a
fuel/waterseparator,drain off any water
that has accumulated.Water in fuel can
seriouslyaffect engine performanceand
may cause engine damage. Detroit
Diesel recommends installation of a
fueVwater separator wherever water
contaminationis a concern.
If a manual transmission is instelled,
check the oil level. Add required transmission fluid to bring the level to the ffulr'
mark on the dipstick. Do not overfill.
Other Check_
The engine may requirethe use of a
cold weather starting aid if the ambient
temperature is below 40°F (4°C).
Check drive belts to make sure they are
in good condition (not crocked, torn,
worn, or glazed)and are properlyadjusted.
Make sure cable connections to the
storage batteries are clean and tight.
Check the hydrometer "eye"of maintenance-free batteries for charge. See
Figure4. if lead-acidor low maintenance
batteries are used, make sure battery
electrolytelevelis normal.
Check turbochargerfor signs of oil or
exhaust leaks.Leaks should be corrected before starting the engine. Check
engine mounting bolts for tightness.
Retighten,if necessary.
_]_
CAUTION:
Starting fluid used in capsules is
highly flammable, toxic, and possesses sleep-inducing properties.
IniUal Engine Start
To start a Series 60 DDEC engine be
sure the transmission is in neutral or
park andtum theignifion keyon.
You will notice that both the "Check
Engine" and "Stop Engine" lights will
come on. See Figure 5. This is the
result of the DDEC computer diognosfunctional,
including the light bulbs for
the "Check Engine" and "Stop Engine"
warning lights. If everything
is okay,
both lights will go out in approximately
Me seconds.
Start the engineafter the lights go
out. If starting a vehicle, start the
engine
foot
the foot
pedal.
ing the with
system
tooff
ensure
everythingis
Eye
Figure4.Check"Eye"ofMaintenance-Free
NONCE;
Batteries
]
If the warning lights stay on, consult t
with a DDEC technician. Operating the /
engineunderthese circumstancesmay
result in engine damage.
J
StarUng the Engine
Before starting the engine the first time,
perform the operations
listed under
Preparations for Starting the Engine
the First Time (pages3-4).
If the engine has an emergancymanmakeorsure
the controlshutdown
is set in the
open
ua,
automatic
system,
position beforestarting.The turbccharger may be seriously damaged if the
_oPo_oea_e
c._K_
J
=_
_.."_'1'1_//
Q
-;_
O
_'/1_1_
me.e
_=
D_St40_11C
sere=,
engine is cranked with the air shutdown
in the closed position.
fTgure5. TypicalShut-OownOvemde
Switchand EngineLights
5
1. Press the starterswitch firmly.
Running the Engine
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
I started,
NOTICE:
Observe the oil pressure gauge immediately after starting the engine. A good
indicatorthat all of the moving parts are
Oil Pressure
getting
lubricationis when the oil pressure gauge registers pressure (5 psi 34.5 kPa at idle speed). If there is no oil
pressure indicated within 10 to 15 secands, stop the engine and check the
lubricating system. Tile pressureshould
not fall below 28 psi (193 kPa)at 1800
rpm, and normal operating pressure
should be higher. If pressure does not
fall within these guidelines,it should be
checked with a manual gauge.
2. If the engine fails to start within 15
seconds, release the starter switch
and allow the starting motor to cool
for 15 seconds beforetryingagaln. If
the engine fails to start after four
attempts, an inspection should be
madeto determinethe cause,
AirStarter--Because of the limitedvolume of most storage tanks and the relatively short duration of the cranking
cycle, it is important to make sure tim
engine is ready to start before activating the air starter. Start an engine
equipped with an air starteras follows:
1. Check the pressure in the air storage
tank. If n_ry,
add air to bring the
pressure up to at least the recommended minimum for starting,
2. With foot OFF the foot pedal, press
the starter button firmly and hold until
the engine starts.
A
CAUTION:
To avoid personal injury from the
hot oil, do not operate a Series 60
engine with rocker cover removed
for any reason.
Warm-up
Run the engine at part throttle for about
five (5) minutes to allow it to warm up
before applying a load.
InspecUon
Stopping l_e Engine
Transmission--While
the engine is
idling,check the automatic transmission
(if equipped) for proper oil level and add
oil as required.Look for coolant,fuel, or
lubricating oil leaks at this time. If any
Normal Stopping
are found, shut down the engine immediatefyand have leaks repairedafter the
enginehas cooled,
Crankcase--if the engine oil was
replaced, stop the engine after normal
operating
temperature
has been
reached. Allow the oil to drain back into
the crankcase for approximately 20 minutes, and check the oil level. If necessary, add oil to bring the level to the
proper mark on the dipstick. Use only
the heaw-duty oils recommended in
Hew to Select Lubricating Oil (page
41) in this guide,
2. Allow the engine to run between idle
end 1000 rpm with no load for four or
five minutes.This allowsthe engineto
cool end permits the turbochargerto
slow down. After four or frye minutes,
shut down the eng_ne.
1. Decrease engine speed back to norreal idle and put all shift levers in the
neutralposition.
NOTICE:
Stopping a turbooharged engine
immediately after high speed operation may cause damage to the turbocharger, as it will continue to tum
without an oil supply to the bearings.
Turbocharger_ake a visual inspection of the turbocharger for oil leaks,
exhaust leaks,excessivenoiseor vibration. Stopthe engineimmediatelyifa leak
or unusualnoiseor vibral_anis noted. Do
not restart the engine unffitP,e cause
of the concern has been inves_gated
and corrected. Authorized Detroit
Diesel service outlets are properly
equippedto peflormthis service.
Emergency
Starting
Jump
The DDEC II electroniccontrol system
operates on 12 volts DC. If a DDEC II
engine with an electronicstarting motor
requires emergency jump starting, do
not exceed 16 volts DC.
ODEC III and DOEC IV electronic
control systems operate on 12 or 24
volts DC. If a DDEC IIIor IV enginewith
an electronic starting motor requires
emergency jump starting, do not
exceed 32 volts DC.
Avoid Unnecessary Idling
Duringbng ecgineidling periodswith the
trensmission in neutral, the engine coolant
temperature may fall below the normal
bustion of fuel
operating
range.
in a The
cold incomplete
engine will cause
corncrenkcaesdilution,formationof lacqueror
gummy depositson the valves,pistons,
NOTICE:
Jump starting with voltages greater I
than those indicated or reversing
battery polarity may damage the
sludge
in the
prolongedof
and rings,
andengine.
rapid When
accumulation
idling is necessary, maintain at least 850
rpm spring/summer and 1200 rpm
falVwinter.
ECM E ectron c Centre Modue.
7
Before attempting to jump starL the
engine, make sure jumper cables are
connected properly(positiveto positive,
negative to negative)and in the proper
sequence(negativeto negativelast),
NOTICE:
NOTICE:
If the warning lights stay on, or if they
do not come on momentarily after
turning on the ignition, consult with a
DDEC technician.
Operating
the
engine under these circumstances
may result in engine damage.
I
Failure to observe this precaution
I can result in aifemator and/or equip-
I _,._._
[ merit damage.
I
Reversing battery poladty can also
result in personal injury caused by
the sudden discharge of electrolyte from the battery vents
and/or the sudden rupture of the
battery case caused by explosion
of internalhydrogen gas.
_B=,
_o_
°_c_"_ _'Z_'_--_/
Figure6. TypicalShut-DownOverride
Switchand EngineLights
The Series 60 DDEC engine is
equipped with an eleclronically controlled fuel injection system. There
are no control racks or mechanical linkage to adjust. This system not only
helps to improve fuel economy and
vehicle performance, it also helps to
reduce cold starting time and increase
initial idle speed for fast engine warmup
and virtualeliminationof cold smoke.
The DDEC engine has no mechanical governor. Engine horsepower, torque, idle, and engine spend are
contained in the internal electronics.
Therefore,there are no mechanicalgovemor spring adjustments for idle and
high spendenntroL
There is no need for a throttle
delay either, since emission control is
performed through the Electronic
Control Moduleor ECM.
The electronicfoot pedal assembly,or
EFPA,eliminatesthe need for any throttle linkage.
DDEC II OPTIONS
Detroit Diesel Series 60 engines
equipped with DDECII electroniccontrol
systems are identified by a "U" in the
sixth position of the model number,
Example:6067GU60.
Detroit Diesel Electronic Controlled
Sefies 60 engines can be equipped with
avafietyof options designed to warn the
operator of an engine malfunction.The
options can range from "Check Engine"
and "Stop Engine" panel lights (see
Figure 6) to automatic reduction in
engine power followed by automatic
engine shutdown.
The powerdown/shutdown option may be activated by low coolantlevel,low oil pressure
or high engineoil or coolarittemperature.
8
DDEC engines have Ule ability to
perform diagnostics for self-checks
and continuous monitoring of other
system components. Dependir_g on
the application, DDEC can also monitor
oil temperature,
coolant temperature,
oil
pressure, fuel pressure, coolant level,
and remote sensors (if used). This diagnostic system is connected
to the
"Check
Engine" and "Stop Engine"
lights to provide a visual warning of a
system malfunction,
The
DDEC
engine
can
be
equipped with an engine protection
system that features a 30 second,
stepped-power shutdown sequence
or an immediate speed reduction
without #mdd_inthe
event a major
engine malfunction occurs, such as low
oil pressure, high oil temperature, or low
coolant level.
Cruise Control
A DDEC-equipped
engine may have
cruise control. Cruise control maintains
a set vehicle road speed or engine
speed setting. The driver has switches
to set, activate, and deactivate the systern (see Figure 7), and a slight depressien of the brake or clutch pedal
deactivates the system as well. The rainimum speed at which cruise control can
be used is 30 mph and 1200 rpm.
The cruise control may also be programmed to permit fast idling using the
cruise control switches. With the engine
at normal idle, transmission
in neutral
and service brake on, turn on the cruise
control "on/off" switch, and use the
"resume"
switch. The engine rpm
should increase to a pre-defined rpm.
The rpm can be raised or lowered from
this point using the "set" and "resume"
NONCE:
switches.
If the engine is equipped
with the
power-down/shutdown
option, there
will be a system override button or
switch which may be used to allow
engine operation for a short pedod of
time. If the shutdown
override button
is not used, the shUtdown will occur in
30 seconds.
_'O
d
I] }l_l_ll-_r_j
_;_,'_l;_
10 _
DDEC engines may also have an
optional 3-100 minute idle shutdown
system. The purpose of this system is
to conserve fuel by eliminating excessive
idling and to allow for a turbocharger
cool down period. To activate the shutdown, the transmission
must be in neu-
_ _
tral, with the engine in idle or PTO
mode.
O
_
FTgure7. TypicalCruise Control Switches
9
The cruise control option willmaim
tain the set speed under normal road
and load conditions, it cannot limit vehiu
cle speeds on down grades if available
engine braking effor_ is exceeded, nor
can it maintain speed on upgrades if
power requirements exceed engine
cruise speed after brake or clutch application, simply activate the "Resume"
switch. Each subsequent touch of the
"Resume" switch will increase cruise
speed by t mile (1.6 km) per hour.
power capability.
Since the DDEC system is electronic, a
DDE@ II Operation
NOTICE:
battery is required to operate the computer.
The system operates at 12 volts.
However,in the event of a power supply
malfunction,the .systerowill continueto
operate at reduced voltage.
At reduced voltage, the electronic
control system will detect a malfunction.
When this occurs the "Check Engine"
light will come on. See Figure 8.
When descending a hill with cruise
control "oft," do not allow the engine
to exceed2,500 rpm under any conditions. Failure to observe this precaution can result in overspeeding and
serious engine damage,
CAUTION:
sToe_= D_snc
To avoid the possibility of vehicle
c.ec*
sTo_
S*_CH \,,_,1l_/f
Detroit
not recomdamageDiesel
and/or does
personal
injury,
mend using cruise control under
the followingconditions:
O
_
o_R,o_
• When it is not possible to keep
the vehicle at a constant speed
(on winding roads, in heavy traffic, in traffic that varies in speed,
etc,).
-'_O11_ O
F_/I_l_\
ENGINE E3NGINE
Figure8. TypicalShut-DownOverride
SwitchandEngineLights
At this point, the Electronic Control
Module wilt go into "Back Up Control."
You should then notice a change in
engine operation, and at this time oartain DDECoptions, such as cruise control, smoke control, and automatic
shutdown, will not function.
The engine will operate only at
reduced rpm. You will be able to operate the vehicle at reduced voltage until
the batteryvoltage has reacheda point
where it wilI no longer function and the
engine will shut down.
You can still operate the vehicle and
proceed to your designation when the
"Check Engine" light (or CEL) comes on.
However, a report should be made to a
DDEC technician as soon as possible.
• On slippery roads (wet pavement, ice or snow-covered
roads, loose gravel, etc.),
On engines equipped with Jaeebs
Engine Brakes, the "Jake Brake"® circuit can be activated by releasing the
EFPA completely to the idle position,
The "Jake Brake" will then operate the
same as on engines with mechanical
governors. To return the vehicle to
10
NOTICE:
An important thing to remember is
that it takes 30 seconds from the time
the automatic shutdown sequence
begins until engine shutdown. Therefore
the operator must press the override
switch just prior to engine shutdown
and continue to do so until the vehicle
can be brought to a safe stop.
The immediate speed reduction
ol_Jon will bring engine rpm back to a
predetermined speed, but will not shut
down the engine.
The engine should not be restarted
after it has beenshut down by the engine
protection system unless the problem
has been locatedandcorrected.
The conditions that will cause the
"Stop Engine" light to comeon are:
• Loss of coolant
• Highoil temperature
• Low oil pressure
• Auxiliaryshutdown
When the "Stop Engine" light comes
on, the computer has detected a
major malfunction in the engine that
requires immediate attestion, it is the
operator's responsibility to shut down
the engine to avoid serious damage,
Since many vehicles are equipped
with the DDEC engine protection system, the "Stop Engine" malfunction is
recorded in the Electronic Control
Module. W'_ the 30 second shutdown
option, the engine will begin a 30 second, stepped, power down sequence
until it shutsdown completely.
To allow for the possibility of the
"Stop Engine" automatic shutdown
function being activated while the vehicle is operatingin a cnticel situation,an
overrideis provided.
In this situation the operator may elect
to "override" the automatic stop engine
sequence by pressing the "Stop Engine
Override"switch, located on the instrement panel, until a safe stop can be
made. The operator only needs to press
the override switch every 15 to 20 secends to prevent engine shutdown from
occurring.
It is important to point out that whenever the "Check Engine" light (CEL) or
the "Stop Engine" light comes on, the
DDEC computer will determine where
the problem is, and will then store this
information in its memory.
_fthe malfunction is intermittent, the
"Ughts" will come on and go off as the
computer senses the changing engine
condition.
A special diagnostic tool (Diagnostic
Data Readeror "DDR') is availablethat
NONCE:
For some applications, holding the
"Stop Engine Override" switch in will
not prevent the engine shutdown
sequence. You must continue to reset
can be plugged intotheengineenmputer
memory to extract informaiton related to
the automatic shutdown system by
pressing the "Stop Engine Override
switch at intervals of approximately
15
to 20 seconds.
the cause of the problem. Ses Figure9.
11
emnoneoterorint
computer memory will remain until it is
erased by a technician.
The malfunction code can also be
obtained by the operator. A "Diagnostic
Request" switch may be provided which,
when pressed, will cause the "Check
Engine" light (CEL) to flash a code number. It will, for example, flash twice ...
pause ... flash five times ... pause. In
otherwords a code25. See Figure10.
Code 25 indicates all systems are
working satisfactorily.
The _odes wilt conttnee to flash and
repeat as long as the check engine
switch is held in the "On" pesitJon with
the ignition on. Other diagnostic codes
are listed in Table 1.
Figure9. DiagnosticDataReaderJ38500
Once the realfunationhas been corrected,the DDEC system va'llreturn the
engine to normal operation,
The DDR can distinguish between
codes now active and those stored in
the historic code memory,
12
Diaonostic Connector
data reader or short pin A to pin M.
The latter method will flash codes at
B
L
Error
Oode #
11
12
13
14
15
16
21
22
23
24
25
26
31
32
33
34
35
36
37
38
41
42
Table
M l_3...J
Description
theOEL.
Error
Code #
Power Take-off Sensor Lo Volt
43
Power Take-off Sensor Hi Volt
44
Coolant Sensor Lo Volt
45
Eng Temp Sensor Hi Volt
46
Eng Temp Sensor Lo Volt
47
Coolant Sensor Hi Volt
48
Throttle Pos Sensor Hi Volt
51
Throttle Pos Sensor Lo Volt
52
Fuel Temp Sensor Hi Volt
53
Fuel Temp Sensor Lo Volt
54
No Codes
55
Power Control Enabled
56
Fault on Auxiliary Output
58
ECM Backup System Fail
61-68
Turbo Bst Sensor Hi Volt
71-78
Turbo Bst Sensor Lo Volt
85
Oil Prs Sensor Hi Volt
86
Oil Prs Sensor Lo Volt
87
Fuel Prs Sensor Hi Volt
84
Fuel Prs Sensor Lo Volt
Timing Reference Sensor
Synchronous Ref Sensor
1. DDEC
1 Rash
II Diagnostic
Description
Low Coolant Level
Engine Ovettemperature
Low Oil Pressure
Low Battery Voltage
Hi Fuel Pressure
Lo Fuel Pressure
EEPROM Error
ECM - NO Fail
EEPROM Memory Failure
Vehicle Speed Sensor
Proprietary Comm. Link
ECM - A/D Fail
Cruise Ctl/Press Gov Ctl Switch
Inj Response Time Long
Inj Response Time Short
Engine Overspeed
Press Gov Ctl - Hi Volt
Press Gov Ctl - Lo Volt
Crankcase Pressure Hi
Cedes
CEL
3 Flashes
Short
Pause
CEL
2 Rashes
Long Pause
Code 13
1 Flash
Short
Pause
Code 21
NOTE: The CEL flashing gives both active and inactive (historic) codes,
Figure 10. CEL Examples
13
NOTICE:
If _hevehicleis equippedwith an gEMsupplieddiagnosticswitch, the _witch.
rr¢_ NOTbe switchedon wf-enoper_ir_ _ vehicie,if _is is done,the diagno_c _
lir_ w_llb9 _cunded, and
thetnrot,e w_ be f0rcedto _e, _ecthg
v_q_eoperation.7_ethrot_ w_ alsogo
to idle if pins "A" and "M" in the
Di_lnos_ Dat_Reader(DD_ connecter
are_
_qer. Th_s
CoodilJon
w_
not oocur when the Diagnostic Data
P_ec_ist_d
_)
A
CAUTION:
The operator of a DDEC-equipped
engine should know the extent of
the warning system on his vehicle,
Jnorder to bringit to a safe stop in
the event of an engine malfunclion. A description of the warning
system and detailed instructions
regarding its operaldenshould be
obtained Irom the owner, the seller er the manufacturer of ffm vehltie. This i_orm._ti0p may also be
obtained at any authorized De_olt
Dk_d _
outleL
CAUTION:
To be confrontedwith
powerdown/shutdown
situationa without
knowing how the system works
cou_ cause the _ehicle to stop in
an unsafe location, posing the
pessibi_j of damage to the vehltie and a it_reat to the safety of the
operator.
! The operator of a DOEC-equipped
vehicle must net attem4_tto use or
read a diagnostic data reader of
any kind while l_e unit is eporating. Doing so can result in loss of
i control, which may cause vehicle
damage and may result in personal ir_uW,
i When engine or electrordcs systern diagnosis is required en a
Welding Precaution
NOTICE:
' DDEC-equlpped vehicle, this must
' be done by a person other than
l the operator. The operator must
maintain control of the moving
vehicle while the assistant performs the rTmgnogts,
To preventdamageto tf_ [:)DECelectron_ccontrol system, disconnectbaltery power a_d ground cable_and the
6 pin power connector at the ECM
(electronic control module) before
welding. Failure to isolate the
DDEC system from high current
flow can result in severe ECM
da/nage.
14
I
I
DDEC Ill/IV OPTIONS
are no control racks or mechanical linkage to adjust. This system not only
helps to impreve fuel economy and vehicle performance, it also helps to reduce
cold starting time and increase initial idle
speed for fast engine warm-up and virtual elimination of cold smoke.
The
DDEC
engine
has
no
mechanical governor. Engine horsepower, torque, idle, and engine speed
are contained in the internal electronics.
Therefore, there are no mechanical govemor spring adjustments
for idle and
high speed control.
There is no need for a throttle
delay either, since emission control is
performed
through the Electronic
Control Module (ECM).
The Electronic Foot Pedal Assembly
(EFPA), eliminates the need for any
throttle linkage.
The DDEC engine has the ability to
Detroit
Diesel Series
60 engines
equipped with DDEC III or DDEC IV
electronic control systems are identified
by a "K" in the sixth position of the
model number. Example: 6067GK60.
Detroit Diesel Electronic Controlled
Series 60 engines can be equipped
with a variety of options designed to
warn the operator
of an engine malfunction. The options can range from
"Check Engine" and "Stop Engine"
panel lights (see Figure 11) to automatic
reduction in engine power followed by
automatic
engine shutdown.
The
power-down/shutdown
option may be
activated by low coolant level, low oil
pressure or high engine oil or coolant
temperature.
Slrop ENGINE
o_.,_
CHECK
_rOp
_,_,l,/_//j
:"
['_ O
:
_,,=_
_.E
perform
diagnostics
for serf-checks
and continuous
monitoring
of other
_
_ DDEC can Depending
onthe
application,
also monitor
oil
temperature, coolant temperature, oil
Figure 11. TypicalShut-Down Override
Switch and EngineLights
pressure, fuel pressure, coolant level, and
remote sensors {if used). This diagnostic
system is connected
to the "Check
Engine" light (CEL) and the "Stop Engine"
light (SI3_ to provide a visual warning of a
D_
s_¢.
NOTICE:
If the wamJng lights stay on, or if they
system malfuncgon.
The DDEC engine
can be
equipped with an engine protec'don
do not on
come
momentarily
aftera
fuming
the on
ignilJon,
consult with
DDEC technician.
Operating
the
engine under these circumstances
system that features a 30 second,
stepped-power shutdown sequence
or an immediate speed reduction
without shutdown in the event a major
engine malfunction
occurs, such as low
oil pressure, high oil or coolant temperature, or low coolant level.
may result in engine damage,
The Series 60 DDEC engine is
equipped wi_ an electronically controlled fuel injection system, There
15
NOTICE:
The DDEC engine may have cruise control. Cruise control maintains a set vehicle or engine speed setting. The driver
has switches to set, activate, and deac
tivate the system. See Figure 12. A slight
depression of the brake or clutch pedal
deactivates the system as well. The rainimum speed at which cruise control can
be used is programmable.
The cruise control may also be programmed to permit fast idle using the
cruise control switehes. W'_ the engine
at normal idle, transmission in neutral
end service brake en, turn on the cruiee
control "On/Oft' switch, and use the
"Resume" switch. The engine rpm
should increase to a pre-defined rpm.
The rpm can be raised or lowered from
this point using the "set" end "resume _
switches.
The cruise conlzol option will maintain the set speed under normal road
and load conditions. It cannot limit vehicte speeds on down grades if available
engine braking effort is exceeded, nor
can it maintain speed on upgrades if
power requirements
exceed engine
power capability.
If the engine is equipped with the
power-down/shutdown
option, there
will be a system override button or
switch which may be used to allow
engine operation for a short period of
time, If the shutdown override button
is not used, the shutdown will occur in
30 seconds. Using the overnde button
so that the engine operates for an
extended pedod may result in engine
damage,
..............
The DDEC engine may also have
an optional 1-100 minute idle shutdown system. The purpose of this system is to conserve fuel by eliminating
excessive idling and to allow for a turbocharger cool down period. To activate the shutdown, the transmission
must be in neutral, with the vehicle parking brakes set and with the engine in
idle or fast idle mode.
Cruise Coln_'ol
p
_
theWhen
on position
the cruise
cruiseenable
control switch
is engaged
is in
"Set/Coast" switch to the on position.
Holding the switch in the on position
allows the vehicle to slow to a lower
by
contacting
speed.momentarily
Toggling this switch
will resultthe
in
vehicle speed, if cruise control has been
disabled, toggling the "Resume/Acoer'
switch restores the vehicle to the previa one mile-per-hour
(1mph)decrease
ously
set cruise speed.
Holding thein
tion allows
the vehicle
speed to
increase. Toggling this switch will result
"Resume/Accel"
in
a one mile-per-hour
switch(1inmph)
the on
increase
posiinvehicle
speed.
Using either the brake or the clutch
will disable cruise control.
Figure 12. Typical Cruise Control Switches
16
NOTICE:
Data Recording Capability
When descending
a hill with cruise
control "off," do not allow the engine
to exceed 2,500 rpm under any conditions. Failure to observe this precaution can result in overspeeding and
senous engine damage,
Standard in all DDEC IV engines is a Data
Recording
capability
called DDEC
Reports. DDEC Reports contain information on driver activities,
engine performance and criticalincidents repaling. This
information is also available in DDEC III,
but must be activated by Detroit Diesel
Corporation at the request of the cus-
CAUTION:
tomer.
Thebeinformation
in both
DDEC
and IV can
e)Cac_ed with
Detroit
Dies_Ill
Diagnostic Unk 2.0 (DDDL 2.0) seltware.
DDEC Ill informa_n only may be extracted with ProManager 2.0 sei_tware.To perform the extraction
at least a 486
computer with 16 MB RAM is requited.
To avoid the possibility of vehicle
damage and/or personal injury,
Detroit Diesel does not recommend using cruise control under
the following condi'dons:
• When it is not possible to keep
the vehicle at a constant speed
(on winding roads, in heavy b-drtic, in ba_c that varies in speed,
etc.),
ODEC III/N
Ol_w'a'don
Since the DDEC system is electronic, a
battery is required to operate the computer. The system operates at 12 or 24 volts.
However, in the event of a power supply
malfunction, the system will continue to
operate at reduced voltage. When this
occurs the "Check Engine" light will come
on. See Figure t3.The engine will only
operate at reduced rpm until the battery
voltage reaches a point where the ECM
will no longer function and the engine
shuts down.
• On slippery roads (wet pavement, ice or snow-covered
roads, loose gravel, etc.),
On engines equipped with Jacobs
Engine Brakes, the Jake Brakes are
enabled by an "On/Of?' switch mounted
on the dash. A separate intensity switch
is used to select low, medium, or high
braking power. The engine brake will
_'_'_._eo_mR©E c._=_
released. Disengaging the clutch will
only operate
when the
,cot from
pedaloperatis fully
prevent
the engine
brakes
ing, also.
dake Brakes will supply braking
power even when in cruise control. Tbe
e/ectronic control module will control the
amount of engine brake with respect to
the cruise control set speed. The maximum amount of braking (Jew, medium,
high) is selected with the dash switches.
_)
_
_c.
stop
:"
_If
0
__//J'l_
_
_-_
Figure 13. TypicalShut-Down Override
Switch and Engine Ughts
17
Should the "Check Engine"light come
on for any reason,the vehiclecan stillbe
operated and you can proceed to your
destination. This condition should be
reportedto aDDECteehnician essoon as
possible,
NOTICE:
For some applications, holding the
"Stop Engine Override" switch in will
not prevent the engine shutdown
sequence.You must continue to reset
the automatic shutdown system by
pressing the "Stop Engine Override"
switch at intervals of approximately
15
to 20 seconds.
NO11CE
When the "Stop Engine" light comes
on, the computerhasdetecteda major
malfunctionin the enginethat requires
immediateatterfdco,it is the operator's
reePOnsibi!ity to sh_ _
the engine
to avoidseriousda_nage,
An importantthingto rememberis that
it takes 30 seconds from the time the
automatic shutdown sequence begins
until engine shutdown. Therefore, the
operator must press the override switch
just prior to engine shutdown and continue to do so until the vehicle can be
broughtto a safestop.
The immediate speed reduction
option will bnng engine rpm back to a
pradeterminedspeed, but wil_not shut
down the engine.
The engine should not be restarted
after it has been shut down by the
engine protection system unless the
problem has been located and corrected.
The conditionsthat willcausethe "Stop
Engine" light (SEQ to come en are:
The engine can be configured to give a
warning only, to ramp down (reduce
power),or to shutdown. Ramp down will
reduce engine rpm to a predetermined
speed, but willnot shut downthe engine,
VCith_qe30 second shutdownoptionthe
engine will begin a 30 second, stepped,
power-down sequence un_l it shuts down
completely. A "Stop Engine Override" can
be supplied in case tbe vehicle isto operatein a critk:alsituation,
NOTE:
The "Stop Engine Override"
and
"Diagnostic Request" switch is the
same.
•
•
•
•
•
In this situation the operator may elect
to "override" the automatic stop engine
sequence by pressing the "stop Engine
Override" switch, k:_cated on the instroment panel, until a sate stop can be
made.The operatoronly needsto press
the overnde switch every 15 to 20 seconds to prevent engine shutdown fror_
occurring,
Highcoolanttemperature
LoSs of coolant
High oil temperature
Low oil pre_ure
Auxiliary shutdown
It is important to point out that whanever the "Check Engine" light (OEL)or
the "Stop Engine" light (SEt_)comes on,
the DDEC computer will determine
wherethe problemis, and willthen store
this information in its memory.
18
If the malfunction is intermittent,
the
"Ughts" will come on and go off as the
computer senses the changing engine
condition.
A special diagnostic tool (Diagnostic
Data Reader or "DDR") is available that
can be plugged into the engine computer
memory to extract information related to
the cause ofthe problem. See F_Jure14.
The malfunction code recorded in the
computer memory will remain until it is
erased by a technician.
The malfunction code can also be
obtained by the operator. A "Diagnostic
Request" switch is provided which,
when pressed, will cause the "Check
Engine" light (CEL) to flash a code number. It will, for example, flash twice ...
pause ... flash five times ... pause. In
Code 25 indicates
all systems are
wori4ng satisfactorily.
The active cedes will be flashed on
the "Stop Engine" light (SEL) in the order
of most recent to least recent occurrence based on engine hours. If there
are no active codes, a cede "25" will be
flashed.
The inactive codes will be flashed
on the "Check Engine" [ight (CEL) in the
order of most recent to least recent
occurrence
on engine
hours.
Other wOrds abased
cOde 25"
See Figure
15" If
there are no inactive cedes, a code "25"
will be flashed.
Note that only one light will be flashing
codes at any time. When code flashing
is initiated, the active codes (or code
"25") will be flashed on the SEL. Then
the inactive codes (or code "25") will be
flashed on the CEL. When all the inactive codes (or code "25") have been
_1
Figure 14. Diagnos#bData ReaderJ3&500
Once the malfunction has been cotrected, the DDEC system will return the
engine to normal operation.
The DDR can distinguish between
codes now active and those stored in
the ECM memory (inactive).
RED = SEL
YELLOW = CEL
SEL--ActiveCodes
1Rash
3 Rashes
Short
Pause
CEL_nact_'eCodes
2 Rashes
1 Rash
LongPause
Code
13
Short
Pause
Code
21
NOTE:TheSELflashinggivesactivecodes.]_e CELflashinggivesinac_rve
(historic)
codes.
Figure 15. SEL/CELExamples
19
flashed,
the process
of flashing
all the
The codes
acfrve codes followed by all the inactive
codes will repeat until the conditions
for
code flashing are no longer satisfied,
Rash
will continue
to flash
and
repeat as long as the diagnostic request
switch is held in the "On" position
with
the ignition on. Other diagnostic
codes
are listed in Table 2.
Rash
Code
DDEC Ill/IV Description
Code
DDEC Ill/IV Description
11 VSG sensor input voltage Low
44
Oil or coolaut or intake air, temp. high
12 VSG sensorinput voltage high
45
Oil pressure low
13 Coolant levelsensor input voltage low
46
ECM battery voltage low
14 Oil or coolant temp. sensor input voltagehigh 47
Fuel. alt inlet, or turbo boost, pressure high
15 Oilorcoelanttemp. sensor input voltage low 48
Fuelorairinletpressurelow
16 Co_l_le(,elsedsor]nl_.fl!vo_tiigh
....
52. ECM_O0"6_)7{v-e'rsi6df_l....
17 q3_ruttievalve position sensor input voltage
53
ECM non volatile memory fault
high
54
Vehicle speed sensor fault
18 Throttle valve position sensor input voltage
55
J1939 data link fault
low
56
J1587 data link fault
21 TPS input voltage high
57
J1922 data link fault
22 TPS input voltage low
61
Injeutor response time long
23
Fueltemp. sensor input voltage high
62
Aux. output shortto battery (+) or open circuit,
24
Fuel temp. sensor input voltage low
or mesh. fault
25
Noactive codes
63
PWMdriveshorttobattery(+)oropenelrcuit
26 Aux. engineshutdown#1or#2, inputactive
64
Turbosgeedsensorinputfauit
27 Air inletor intake air, temp. sensor input volt
65
Throttle valve position input fault
age high
66
Engineknock sensor input fault
28 Air inlet or intake air, temp. sensor input volt
67
Air inlet pressure sensor input voltage fault
age low
68
33°S idle validation switch open circuit or short
31 Aux. high side output open circuit or short to
to ground
ground
71
Injector response time short
;32 CELorSELshorttobattery(+)oropenelrcult
72
Vehieleoverspeed
33 Turbo boost sensor input voltage high
73
Gas valve position input fault or ESS fault
84 Turbo boost input voltage low
74
Optimized ldlee satety loop short to ground
35 Oil pressuresensor input voltage high
75
ECM battery voltage high
36 Oil pressuresensor input voltage low
76
Engine overspeed with engine brake
37
Fuel pressuresensor input voltage high
77
FuelTemperature High
88
Fuel pressure sensor input voltage low
85
Engine overspeed
41 Too many SRS (missing TRS)
86
Exfamal pump pre&sure sensor input voltage
42 Too few SRS (missing SRS)
high
48
Coolant level low
87
Extemal pump pressure sensor input voltage
low
TO READ CODES: Use the diagnostic data reader or depress and hold the diagnostic request s_Crfah
with the ignition on, engine at idle or not running. Press and hold the sw_ch. Active codes will bc
flashed on the "Stop Engine" light (SEL) followed by the inactive codes being flashed on the "Check
Engine" light (CEL). The cycle will repeat until the operator releases the diagnostic request switch.
Table 2. DDEC IllIV System Diagnostic Codes
2O
Welding Precaution
A
NOTICE:
To preveqt damage to the DDEC etec_ic
cor_f _ule
and other DDEC
compor_nts, disconnect batte_/power
and ground cables and_ 5-pin power
connector at the E-CM(electToniccon_ol
module) 10¢_ore
welding. Faillureto isolate the DDEC system from high
current flow can result in severe
ECMdamage.
A
CAU'RON:
The operator of a DDEC-equipped
vehicle must not attempt to use or
read a diagnostic data reader of
any kind while the unit is operating. Doing so can result in loss of
control, which may cause vehicle
damage and may result in personal injury.
When engine or electronics system diagnosis is required on a
DDEC-equipped
vehicle, this must
be done by a person other than
the operator. The operator must
maintain control of the moving
vehicle while the assistant performs the diagnosis.
CAUTION:
The operator of a DDEC-equq)ped
engine should know the extent of
the warning system on his vehicle,
in order to bring it to a safe Stop in
the event of an engine malfunction. A description of the warning
system and detailed instructions
regarding its operation should be
obtained from the owner, the sell; er or the manofactarer of the vehii de. This information may also be
obtained at any authorized De'aoit
Diesel service ou_at.
To be confronted with a powerdown/shutdown situation wi_out
knowing how the system works
could cause f_e vehicle to stop in
an unsafe location,
posing the
possibility of damage to the vehicle and a threat to the satety of the
operator.
21
DDEC Ill/IV ENGINE DRMNG
Accelerating
the Vehicle
TIPS
switch to activate cruise control. The
cruise light wili come on. To increase
road speed in one MPH increments,
press the reeume/eccel switch. To
reduce road speed, press and hold the
set/coast switch entilthe lower speedis
reached. Cruise control is deactivated
by slightly depressing the service brake,
clutch pedal, or trailer brake. Also, the
on/off switch deactivatescruise control
Cruise control will raaintain speed even
on upgrades, unless power requirements demand a downshift. And, of
course, cruise control doesn't limit your
speed on down grades. Most likely, the
cruise control will feel stronger than
driving with the foot pedal because of
the instantaneous and wide open throttie response. That is why cruise control
use is not suggested during slippery
driving conditions.
Use cruise control after down shifting
on a hill to pu]I the hill. Hitting the
resume switch (not the set switch) will
keep the truck accelerating in the lower
gears up to rated engine speed.
Cruise control will disengage below
1100 RPM or 20 MPH road speed.
When using cruise control, it you want
to pull the engine below 1100 RPM,
remember to hold the throttle pedal to
the floor to keep the engine pulling at
wide-open throttle. Realistically, the
engine will pull to about 1050 RPM.
Remember: The electronic data programmed into the ECM will not allow
you to hurt or overfuel the engine at low
or lug engine speeds. There is enough
oil pressure to withstand hard pulls at
low engine speeds.
Engine response versus pedal movement may feel different from the
mechanical governed engine you were
driving. The electronic foot pedal
assembly was designed to communipate "percentage"
foot pedal travel to
the engine's electroniccontrol module,
The engine will respond accordingly to
tbe driverL& d_
...............................
Another throttle or governor charecteristic you may need some time to get
usedto is the DDEClimitingspeed governor. This allows the driver to cornmand total engine response between
idle and rated speed, such as accalerating at half throttle - an advantage when
driving under slippery conditions,
If you do require wide open throttle
engine response, either accelerating or
just plain pulling hard, the throttle will
have to be held to the floor. To obtain
100% fueling at any speed, the foot
pedal will have to be maintained at the
fully depressed position,
Cruise Conbol
For added driver convenience and
comfort, DDEC IIIalso featuresa cruise
control option which works just like the
system in your car. It can be operated
in any gear above 1100 RPM or road
speed faster than 20 MPH, up to the
rated engine speed. And it can be programmed to hold your road speed at or
below the maximum vehiclespeed. The
switch to energize cruise control is usually mounted on the instrument panel,
Turn the switch to the on position to
energize the system. When you
reached your road speed, press the set
22
Jake Brakes
If you decide to drive at lower RPM's
for improvedfuel economy, don't letdifferent engine noises throw you off
guard. The Series 60 sounds quiet at
1400 RPM, almost as if it had quit
pulling. Don't believe it! If you had a
boost gage to look at while drMng, you
would notice the turbcoharger malntalning steady intake manifold pressure,
even as RPM's fall. Depending on the
air intake arrangement, you may also
experience a "chuffing" sound as the
engine starts to pull hard at the lower
RPM's. This is caused by the velocity
changes of the air flow within the air
intake plumbing. Electronicenginescan
actually deliver more fuel at lower engine
speeds than at rated speed.
If your engine is equipped with both
cruise control and Jake Brake ®
retarders, the Jakes can operate automaticallywhile you are in cruise control,
If the cruise contreVenginebrake func
tion is turned on in the ECM programming, the Jakes will come on "low"
when your set road speed increases a
few MPH or KPH above your cruise set
speed. If your speed continues to
increase, the ECM will increase the
Jakes' braking power progressively.
When the vehicle returns to the set
cruise speed, the Jakes will "turn off'
until the next time you need them. For
safety reasons, don't use cruise control
when it's not possible to keep the vehi-
Idling
cle at constant speed due to winding
roads ... heavy traffic ... slippery roads
... or when descendinggrades that call
for Jake Brake assistance,
The common belief that idling a diesel
engine causes no engine damage is
wrong. Idling produces
sulfuric acid
which breaks down the oil and eats into
bearings, rings, valve stems and engine
surfaces.If you must idle the enginefor
cab heat or cooling, the high idle function of the cruise control switches
should be utilized. An idle speed of
1100 RPM should be enough to provide
cab heat in above 32°F (0°C) ambiects.
A winter front may be used to improve
cab heating while idling, but it should
never cover more than 3/4 of the grill
while driving. Winter fronts should only
be used when the ambient temperature
remainsbelow 10° F (-12.2° C).
Sh;[Ung
Dependingon your transmissionmodel,
the gear split may varyfrom 500 to 300
RPM. The electronic governor provides
aJmost no overrun capability; and if the
transmission is downshifted too early,
you will expenecce a temporary loss of
pulling power until the engine speed falls
below rated speed. In general, when
using a 7 or 9-speed transmission,you
should always downshift between 1250
and 1300 RPM. This is true even on
steep grades with heavy loads. When
using an 18, 15 or 13 speed transmission, you will need to downshift at an
RPM that allows "less than rated" RPM
before throttle application
in the next
gear down. You may want to limit
engine speed to 1900 RPM in all gears.
The Sehes60 provides constant horsepower from 1800 RPM through 2100
RPM, but fuel economy is not as efficient above 1800 RPM.
23
ENGINE SYSTEMS
engines. This system has a centrifugal
type fresh water pump to circulate
coolant within the engine. Two full
blocking type thermostats located in a
housingattachedto the right side of the
cylinderheadcontrol the ifowof coolant.
Fuel System
The fuel system consists of the DDEC
electronic fuel system controls, fuel
injectors,fuel manifolds(integra]with the
cylinder head), fuel pump, a cooling
plate for the electronic control module
(ECM) on non-automotive
engines, pfimary and secondaryfuel filters,and the
necessaryconnectingfuellines,
The primary filter (marked "P") or
combinationfilter and fuel/water _ara{or r6m0ves large impurities {rom {he
fuel. The secondary filter (marked =S")
removesthe smallerparticles,
Electrical
System
The electrical system consists of a starting motor, starting switch, batterycharging alternator, storage batteries,
and the necessarywiring.
Exhaust _m
Hot exhaust gas flowing from the
exhaustresn#oldintothe exhaustriseris
Lubrication System
usedto d_e the turbcoharger.
I_aJntenan¢e
Interval
Schedules
The lubricaitngoil system consistsof an
oil pump, oil cooler,two fullllow oilfilters,
bypassvalvesat the oilpumpand oil filter
adapter, and pressureregulatorvalve in
the cylinderblockverticaloil gallery,
Recommended maintenance intervals
for Series60 on-highwaytruck and parlor coach enginesare listed in Table 3.
Air System
Recommended maintenance intervals
for Series 60 transit coach engines are
listed in Table 4. Recommended maintenance intervals for Series 60 construction4ndustdaiand stationaryenginesare
listed in Table 5.
In the air system used on Series 60
engines, outside air drawn into the
engine passes through the air filter and
is pulled into the turbcoherger, where it
is compressed, it then moves to the airto-air charge cooler (heat exchanger)
where it is cooled. From here it flows to
NOTICE:
the intake manifold and into the cylinders, where it mixes with atomized fuel
fl'om the injectors,
Dry type air cleaners are used on
Series 60 engines. For optimum protection of the engine from dust and other
airborne contaminants, service these
air cleaners when the maximum
allowable air restriction has been
reached, or annually, whichever
occurs first,
Coolantmust be inhibitedwiththe rec-
Cooling System
engine cooling system and related
components.
ommended SCA's (supplemental
coolant add_ives)listedin the "How to
Select Coolant" section of this engine
operator's guide. In addition, the engine
can be equipped with a coolant
filter/inhibitor system as an installed
optionor as an after-saleitem. Failure
to check and maintain SCA ]evels at
required concentrations will result in
severe damage (corrosion) to the
A radiator/thermo-modulated fan cooling system is used on Series 60
24
ITEM
1--Lubdca'dng Oil"
_uel
DAILY
MAI NTENAN
Unesand FlexibleHoses*
_inq
_stern*
5---Turbocharqer*
ITEM
7500 MILE (12,000 KM) iNTERVAL
6_ery*
_rive
Belts*
SERVICE
RECOMMENDATIONS
_Air Compressor*
ITEM 15,000 MILE (24,000 KM) INTERVAL
1_._ubr,:catJng
Oil*
ON-HIGHWAYTRUCK
OR PARLORCOACH
1;_-.oolant Pumjo/InhibitorLeve£
l_-_rankin 9 Motor*
I
33_bration
CODES:
!
!
!
!
Damper*
l-Inspect, Service, Correct or
Replace as Necessary
Table 3. Engine Maintenanc_n-Highway
B-Reptace
*See item in Text
Truck and Parlor Coach
25
!
1
!
!
DALLY
1 Lubricating Oil*
2--Fuel Tank*
3_FueJ Lines and Flexible Hoses*
MAINTENANCE
_stem*
5_Tu rbochar e.g_
ITEM
7500 MILE (12.,000KM) INTERVAL
SERVICE
8--Drive Belts*
9--Air Compressor*
_8attery*
ITEM 15,000 MILE (24,000 KM) INTERVAL
1--Lubricating Oil*
27
Vibration
CODES:
_
Damper*
I-Inspect, Service, Correct or
Replace as Necessary
Table 4. Engine Maintenance--Transit
R-Replace
*See Item in Text
Coach
26
RECOMMENDATIONS
TRANSIT COACH
ITEM
DAILY
1 Lubdoating
Oil*
3,--Fuel Unesand RexibleHoses*
_lin
era*
5_Turbocha_
2--Fuel Tank*
ITEM
100HOURS3,G00
MILES
_Battery*
8_Ddve Belts*
ITEM
150 HOURS 4,500 MILES
t--LubncatJng O_*
_i
MAINTENANCE
SERVICE
RECOMMENDATIONS
_
9-_AJr
Compressor*
10_AJr Cleaner*
11--Lubncating Oil Rlter*
12_uel Rlters*
ITEM
200 HOURS 6,000 MILES
1_oolant/Inhibitor
7_achometer
Drive*Leve_*
STATIONARY
INDUSTRIALENGINES
_1_
CONSTRUCTION/
ITEM
] mLE_ (10_)
1--Lubricating
Oil*
2--Fuel Tank*
7_Tachometer
Drive*
_r
_mpressor*
11--/ubdcalJng Oil Filter*
12_uel
Fqlters*
l_ant
t _rankJng
CODES:
PumpAnhibitorLevel*
Motor*
I-Inspect, Service, Correct or
Replace as Necessary
Table 5. Engine Maintenance--Stationary
OR
R-Replace
*See Item in Text
and Conetruction/Industrial
27
Engines
LUBRICATION
AND
PRE-
Item I - LubricaUng
VENTIVE MAINTENANCE
INTERVALS
Check the oil level daily with the engine
stopped. If the engine has just been
stopped
and is warm, wait approximately 20 minutes to allow the oil to
drain back to the oil pen before checking. Add the proper grade of oil to maintain the correct level on the dipstick. See
Figure 16.
The following is intended as a guide for
establishing
preventive
maintenance
intervals. The recommendations
given
should be followed as closely as pessible to obtain long life and optimum performance
from Series 60 engines.
Intervalsindicated on the chart are time
(hours) of actual operation.
The intarvaie shown ap_y oalyrtO the
maintenance functions described. Tnase
functions
shou]d be coordinated
with
other regularly scheduled
maintenance.
The "daily" instructions apply to routine or daily starting of an engine. They
de not apply to a new engine or one
that has not been operated for a considerable period of time. For new or
stored engines, refer to the Series 60
Engine Service Manual (6SE483).
Follow instructions given in Section 13.1
under Preparations for Starting the
Engine the First Time.
Preventive maintenance other than
the "daily" checks should be performed
by authorized Detroit Diesel service outlets. These outlets have "ahatrained personnel and special tools to properly
perform all services.
I
O
MILES
PER
QUART
300
Oil
/
/
F-igure 16. Check Oil Level Daily
All diesel engines are designed to use
some oil, so the periodic addition of oil is
normal. See Figure 17, "Engine Oil
Consumption Guidelines" to determine
the degree of oil usage.
]
NOTIC_"
Do not overfill. Oil may be blown out
through the crankcase breather if the
crankcase is overfilled.
J
I.,G.
I
500
".ESV,OE,S
"'G"
700
1500
LOW
Kilometers-miles
x 1.6. Foroff-highwayapplications
1 hour=33miles.
• Have your engine serviced by an authorizedDetroit Diesel service facility at the eadiest opportunRy.
Figure 17. Engine Oil Consumption Guidelines
28
NOTICE:
Item 2 -- Fuel and Fuel Tank
[f the oil ievel is constantly above norrnel and excess lube oil has not been
added to the crankcase, consult with
an authorized Detroit Diesel service
outlet for the cause. Fuel or coolant
dilution of lube oil can result in serious
Keep the fuel tank filled to reduce een_
densation. See Figure 18. Before adding
fuel, refer to How to Select Fuel Oil in
the How To section of this guide.
engine
damage.
_
#_
Before adding lubricating oil, refer to
How
in the
How to
To Select
section Lubricating
of this guide.OilChange
_'_-_.,_,_._
_
_
lubricating oil and filters at the intervals
listed in Table 5 when using fuel with a
sulfur content of less than 0.5 mass
percent. When using fuel with a higher
sulfur content,
refer to When to
Change Oil in the How To section,
_,_._
Senate
Application
Lube Oil/Filter*
Change Interval
Highway Truck
& Motor Coach
Industrial and
Agricultural
15,000 miles or
24,000 kilometers
250 hours or I yr.,
whichever comes
first
Stationary Units
Continuous
200 hours or
3 months,
whichever comes
first
Statbnary Units
Standby
150 hours or
1 year, whichever
comes first
F_gure18. Keep TankFilledto Reduce
Condansatlon
Refill the tank at the end of each
day's operation to prevent condensation
from
contaminating
the
fuel.
Condensation formed in a partially filled
tank promotes the growth of microorganisms that can clog fuel filters and
restrict fuel flow. To prevent microbe
growth add a biodde to the fuel tank or
primary fuel supply. Follow manufacfurer's usage, handling, and safe_ recornmendations.
Water accumulation can be controlled
by using additives containing methyl
carb_[ol or butyl cellueelve. Follow manufacturer's usage, handling, and safety
precautions.
Open the drain at the bottom of the
fuel tank every 30,000 miles or 48,000
km (300 hours for industrial applications)
to drain off any water and/or sediment.
Even/ 12 months or 120,000 miles
(192,000 kin) (600 hours for lodustfial
applications) tighten ell fuel tank mount-
*Change both full-flow ltiters when 1abe
oil is changed,
Table 5. RecommendedEngine Oil Drain
and Fliter Change Intervals
(DieselFuelSulfur Content Less
Than0.5 Mass %)
29
ings
thetank
same
time,
checkand
the brackets.
seal in theAtfuel
cap,
the
A
_
breather hole in the cap and the condition of the flexible fuel lines. Repair or
replacethe parts,as necessary,
NOTICE:
CAUTION:
Personal injury and/or property I
damage may result from fire due
to the leakage of flammable fluids
suchasfuelor ubeo .
Galvanizedsteel fuel tanks, f_ings, or
Service life--A hose has a finiteservice
supply lines should never be used
life. W'rththis in mind, all hoses should
because the fuel oil reacts chemically
be thoroughly inspected at least every
with the zinc seating to form powdery
500 operating hours (1,000 hours for
flakeswhich can quick_ clog the fuel
fire-resistant fuel and lubricating oil
filtersand <Jamege4he--f_,ai
pump and ...... hoses) and/or annually.Leekfor cover
injectors,
damage and/or indications of twisted,
worn, crimped, brittle, cracked, or leakItem 3-- Fuel Lines, Flexible Hoses
ing lines. Hoses with their outer cover
Pre-Start Inspection--Make a visual
check for fuel leaks at all engine-mounted fuel lines and connections, and at the
fuel tank suction and return lines. Since
fuel tanks are susceptible to road hazards, leaks in this area may best be
detected by checking for accumulation
of fuel under the tanks. Check hoses
daily as part of the pre-start inspection,
Examine hoses for leaks, and check all
f_ings, clamps, and ties carefully. Make
sure that hoses are not resting on or
touching shafts, couplings, heated surfaces including exhaust manifolds, any
sharp edges, or other obviously hazardous areas. Since all machinery
vibrates and movesto a certain extent,
clamps and ties can fatigue with age.To
ensure continued proper support,
inspect fastenersfrequently and tighten
or replacethem as necessary,
if fittings haveloosenedor cracked or
if hoses have rupturedor worn through,
take corrective action immediately.
Leaks are not only potentiallydetrimantal to machine operation, but they can
also result in added expensecaused by
the need to replacelost fluids,
worn through or damaged metal reinforcemantshouldbe consideredunfit for
further service.
All hoses in and out of machinery
should be replaced during major overhaul and/or after a maximum of five
years of service. Fire resistant fuel and
lube oil hose assemblies do not require
automatic replacement after five years
service or at maior overhaul, but should
be inspected carefully before being put
back into service.
Item 4 - Cooling System
Jb,
A
CAUTION:
Do not remove the pressure controt cap from the radiator or
attempt to drain the coolant until
the engine has cooled. Once the
engine has cooled, use extreme
caution when removing the cap.
The sudden release of pressure
from a heated coolin9 system can
result in a loss of coolant and possible personal injury (scalding, eye
injury, etc.) from the hot liquid.
3O
Chock the ceeiant level dally and maintaln it near the bottom of the ifiIer neck on
the radistor. Qn some installations this is
Refer to How to Select Coolant for
required test intervals and inhibitor levels.
Coolant
Drain Interval--Detroit
Diesel recommends replacing cooiant at the intervals listed in Table 6.
A coolant system properly maintained
and protected
with supplemental
coolant inhibitors can be operated up to
the intervals shown below. At these
intervals the coolant must be drained,
disposes
of in an environmentally
responsible manner, according to state
and/or federal EPA Refer to "Inhibitor
Test Procedures" under How to Select
Coolant and use the required supplemental additives or filter/conditioner alements listed in Tables 20-26 of the
Specifications Section.
done by chocking an overflow bottle or
sight glass. Add coolant as necessary,
but
overfill.Before
referdoto not
How
to Select adding
Coolantcoolant,
in the
How To section of this guide,
Make a dally visual check br cooling
system leaks. Look for an accumulation
of coolant when the engine is running
and when it is stopped. Coolant leaks
may be more apparent on an engine
when it is cold.
The inhibitors
in antifreeze
solutions
should be replenished with a non-chromate corrosion
inhibitor supplement
when indicated by testing the coolant.
CoolantType
CoolantReplacement Intental
A50/5OmixofPQWERCoatfullyformul_ed
inhibitedethyleneglycolandreezeand wateror
a 50/50 mixof fullyformulatedinhibitedpropyloneg_,col_e
andwater,
W'#hpropermaintenance1 ccolantcon Ice
operated2years,300,000 miles,(480,000
km),or 4,000 hours,whichevercomesfirst.At
thistimethe coolingsystemmustbe completely drained and cleaned before refill.
A 50/50 mixof phcephate-fTee
TMC RP-329
'%ype A" (Ethylene Glycol) or TMC RP-3.30
'q-ypeA" (PropyleneGlycol)antifreezeand
water,
Wrthproper maintenance1 coolantcan be
operated for the life of the engine until
overhaul2 Atthis time the coolingsystemmust
be completelydrainedandcleanedbeforerefill.
W'_ proper maintenance coolant can be operated6 years,600,000 miles,(960,000kin), or
8,000operatinghours,whichevercomesfirst.3
At this time the cooling system must be completelydrdned and aieanedbeforerefill.
A 50/50 rnixof NOAT(NitritedOrganicAck:l
Technology) coolant and water.
1 Proper maintenance involves pedodic evaluation using Power Trac 3-Way Coolant Test Strips and the
addition of required SCA, as indicated by the test strip,
2To verify coolant aeseptability, submit a sample to DDC for coolant analysis every 3 years, 300,000
miles,{480,O00 kin), or 6,000 operating hours, whichever comes first. Submit sample in Power Trac
Coolant Test Bottle, par_ number 26608774.
3NOAT coolants require the addition of an extender
Use 1 pint to 20 gallons of NOAT coolant.
Table 6. Coolant
Drain Intervals
31
every 200,000 miles, (320,000 km), or 4,000 hours.
Cooling System Hoses_AII cooling
system hoses should be inspected at
least every 500 hours for signs of deterlorationand replaced,if necessary.
Item 6_.
Battery
CAUTION:
To avoid possible personal injury
and/or engine damage from accidental engine startup, always d'm-:
connect
the battery
before
servicing the electrical system. To
avoid alternator damage when
removing battery connections,
disconnect the negstive (-) termi: nal first. Reconnect the negative
terminaf 1_ ..............................
Item 5 --Turbocharger, Air-to-Air
Charge Cooler
CAU'RON:
TO avoid personal injury or turbocharger
damage, do not
remove, attach, or tighten turbo_a-I_gel" air lilt ake '¢li_il_ir _¢_ige
the engine is operating or operate
the engine with the ducting
removed.
Checkthe hydrometer"eye"of maintenance-free batteries for charge. See
Visually inspect the mountings, intake
and exhaust ducting and coanections for
leaks daily.Check the oil inlet and outlet
lines for leaks or restdctians to oil flow.
Check for unusual noise or vibration and,
if excessive,stop the engineand do not
operateuntilthe cause isdetermined.
Periodically
inspect the air-to-air
chargecooler(if used)fordirt, mud,etc.
buildup and wash off. Check the cooler,
ductwork, and flexible connections for
leaks and have repairedor replaced,as
required.
Check heat-insulating exhaust system
blankets('rFused)for damagedaily. Torn,
matted, crushed, oil-soaked, or otherwise damaged insulation blankets must
be replaced immediately.
Figure 19. If lead-acid or low maintenance batteries are used, check the
specific gravity of each cell every 150
hours. Check more frequently in warm
weather due to the more rapid loss of
water throughevaporation.
Eye
Figure19.Check"Eye"ofMaintenanceFreeB-B-B-B-B-B-B-B-B-B_tenes
32
Maintain the electrolyte level accord-
Item 8 -- Drive Belts
ing to the battery manufacturer's recommendations, but do not overfill,
Overfillingcan cause poor performance
or esdyfailure,
Keep the terminal side of the battery
clean. When necessary, wash with a
solution of baking soda and water,
Rinsewith fresh water. Do not allow the
soda solutionto enterthe cells,
Inspect the cables, clamps, and holddown brackets regularly. Clean and
reapply a light coating of petroleumjelly
when needed. Have corroded or damaged parts replaced,
If the engine is to be out of servicefor
more than 30 days, removethe batteries and store in a cool, dry place. Keep
batteries fully charged, if possible.
Replace any battery that fails to hold a
charge,
Periodically check battery connections for corrosion end tightness.If necessary, remove connections and wire
brush any corrosion from terminalsend
cableends. Replacedamagedwinng.
Item 7-- Tachometer Drive
A typical tachometerdrivetake-off Iooa
tion is the camshaft drive gear access
cover on the front of the gear case
cover. Lubricetethe tachometer drive (if
Belts should be neither too tight nor too
loose. Belts that are too tight impose
excess loads on the crankshaft, fan
and/or alternator bearings, shortening
both belt and bearing ]ife. Excessively
overtightened belts can result in
crankshaft breakage. A loose belt will
slip and may cause damage to accessery components.
Use a Belt Tension Gage, such as
Kent-Moore tool J 23586-B (V belt),
J 23600-B (Poly-V belt), J 41251 -B
(PowerBand®and 12-Rib Poly-Vbelt)or
equivalent, when tensioning drive belts.
Tension belts to the values listed in
Table 7.
FAN DRIVE
SINGLEBELT
2 OR3 SELTS
80-100Ibs
60-80Ibs
ALTERNATOR
DRIVE
BELT
NEW
USED
TWO1/2"
125Ibs
100Ibs
V-GROOVE
2-GROOVE
200 Ibs
150 Ibs
POWERBAND
®
12-RIBPOLY-V 350 Ibs
250 Ibs
50 DNALT.
Table7.DriveBet Tensioning
so equipped)every 150 hours or 15,000
miles (24,000 kin) with an all purpose
grease. At temperatures above -1°C;
(+30OF),use a No. 2 grade grease. Use
V-Belts--New
standard V-belts will
slretch alter the firstfew hours of operatien. T_htenV-Ice_ts
es shownin thechart.
Run the enginefor 10 to 15 minutesto
seat the belts, then readjust tension.
Check and retensionbelts alter 1/2 hour
or 15 miles and again aiter 8 hours or 250
miles (400 km) of operation. Thereafter,
chen_ the t_
of the drive belts evey
100 hours or 6,000 miles (10,000 I_n) and
adjust, _ ne:esss_.
a No. 1 grade grease below this ternperature.
33
If a belt tension gage is not available,
Item 9-- Air Compressor
adjust the belt tension so that a firm
All air compressorair intake parts should
bush with the thumb, at a point midway
be removed and cleaned at these interbetween the two pulleys, will depress
vals:
the belt 12.70-19.05 mm (.500"-.750').
• On-highway vehicle engines -2-Groove PowerBand®--Tighten a
7,500 miles(12,000km)
new belt to 200 Ibs,then run the engine
• InduStrialengines -- 150 hours or
for 10 minutes at 1200 rpm. Stop the
4,500 miles(7,200kin)
engine and allow a 10-15 minute cool
To clean either the haip or polyuredown period. Check tension. If less than
thane-type compressor air strainer eIe150 Ibs, retensionto 150 Ibs. Following
ment, saturateand squeezeit in fuel oil,
initial tensioning, measure belt tension
or any other cleaningagent that would
every rd0nth _t e_ety 7,500 mites
not be detfimentaltdthe element,unifl It
(121600 krn}i whicR&ver comes firs{. ........is'dlrt-_eel]_q_r_';
dip'_Se-d_6_'in IQb_i:
Retansion belt to 150 Ibs at these intercating oil and squeeze it dry before p]acvals.
ing it back in the air strainen
12-Rib Poly-V Belt--Tighten a new
belt to 350 Ibs then run the engine at
high idle for 30 minutes. Stop the engine
and allow a 10-15 minute cool down
period. Check tension with tool J
41251 B or equivalent, if 250 Ibs or
more, no retensioning is required. If less
than 250 lbs, retension to 250 Ibs.
Measure belt tension every month or
every 7,500 miles (12,000 km), whichever comes first. Retension to 250 Ibs as
required,
Drive belts (V and Poly-V) should
be replaced every 2,000 hours or
100,000miles (160,000km).
Replace ALL belts in a set when
one is wom. Single belts of similarsize
should not be used as a substitute for a
matched belt set. Premature belt wear
can result because of belt length varation. All belts in a matched belt set are
within .032" of their specified center
distances,
When installing or adjusting an
accessory drive belt, be sure the
bolt at the accessory adjusting pivot
point is properly tightened, as well
as the belt in the adjusting slot.
For replacementof the air strainerelement, contact the nearest servicing
dealer; replace with the polyurethane
element, if available.
Every 12 months or 30,000 miles or
48,000 km (300 hours for industrial
applications) the air compressor mounting bolts should be tightened.
Item 1e--Air Cleaner
The air cleaner element should be
inspectedevery 15,000 miles (24,000
km) for vehicle engines, 150 hours for
non vehicleengines,or moreoften if the
engine is operated under severe dust
conditions. Replacethe element If necessary.Checkthe gaskets for detefioration and replace, if necessary, if the dry
type air cleaneris equippedwith an aspirator, check for aspirator damage or
clogging. Cleanand repairas necessary.
Under no engineoperatingconditions
should the air inlet restrictionexceed 20
inches of water (5.0 kPa). A clogged air
cleaner element will cause excessive
intake restrictionand a reducedair supply to the engine.This, in turn, can result
in increasedfuel consumption,inefficient
engine operation and reduced engine
life.
34
Dry-type air cleaner elements
should be replaced after one year of
serviceor when tile maximumallowable air intake restriction has been
_
comes r._. Re#er
to When to Sen4ce the Dry Type Air
Cleaner(page65).
Inspect the entire air system for leaks
daily. Look especially for tom air inlet piping or boots and loose or damaged
clamps. Have worn or damaged parts
Item 12-- Fuel Filters
Spin-on -- Installnew spinon fuel filler
elements (see Figure 21) on vehicle
enginesevery 15,000 miles(24,000 km)
or every six months, whichever comes
first. Installnew spin-onfilterelementson
non-vehicle engines every 150 hours.
Replace spin-on elements immediately if
plugging is indicated, regardless of
mileage or hour intervals.
repaired or replaced, as required.
Retightenanylooseconnections.
. _ _f_
_L--_:__1_,
_\_"_'_
Item 11 -- LubricatingOil Filters
Install new spimon oil fillers (see Figure
_
_._J
20) at akm)
maximum
15,000 ormites
(24,000
on vehicleofengines
150
hours on industrial enginesor each time
the engine oil is changed, whichever
comes first. Installthe new filters,turning
I_/
_--_/
@_
(/
PRIMARYt
FUELRLTER
them
contact the
with nountil
sidethey
movement.
Turn gasket
full-flow fully
filtersan additional2/3 rumby hand.
Rgure21.SpinOnFuelF_lt_Locations
[_
_\/;ol
,
_
SHU'r'_OFF
/
_w
SECONDARY/
FUELFILTER
Fuel Pro® 880_ Install new Fuel Pro
3__-e_.
,_./_
380sea-through
the
filter element
cover
when
reaches
the fuel
the levelin
top of
whichever
comes first.
NOTE:
Filterchangeintervalsmay be shortened
to conform with established preventive
maintenance
schedules,
but should
never be extended.
the dement or after one year of senace,
Figure20.Lubricating
OilFilters
Make a visual inspection of all lubricatingoil linesfor wearand/or chafing.If any
indicallon of wear is evident, replace the oil
lines and correct the cause.
Check for oil leaks after starling the
engine.
35
A method of determiningwhen filters
are plugged to the extent that they
should be changed is based on the fuel
pressure at the cylinder head fuel inlet fitting and the inlet restriction at the fuel
pump. In a clean system, the maximum
pump inlet restrictionshould not exceed
6 inchesof mereury(20.3kPa)and must
not exceed 12 inches of mercury (41
kPa) with a dirty system.
At normal operatingspeeds and with
[['_
I_
Figure22.CoolantInhibitorElement
the standard.080" restrictionfittings,the
fuel pressure is 375-483 kPa (55-70 psi.
Ohm6 the fuel1iEers'_eear the inlet....
restriction at the fuel pump reaches 12
inches of mercury (41 kPa) at normal
operatingspeeds and wheneverthe fuel
pressure at the inlet fitting falls to the
minimum fuel pressure of 6 inches of
Item 14 _ Cranking Motor
.............
For ]dformati0d, Contactan authorized
Delea-Remy¢ ServiceCenter.
Item 15-- Air System
mercury(20.3kPa).
All the connections in the air system
should be checked to make sure they
are tight. Check all hoses and ducting
Item 13-- Water Pump and Coolant
Inhibitor Element
for punctures, deterioration or other
damageand replace,if necessary.
The water pump drain hole should be
inspectedevery 6 monthsto make sure
if is open. A small chemical build up or
streaking at the drain hole may occur,
This is not an indication of a defective
water pump or seal. Removethe buildup with a mild detergent cleanerand a
brush. If coolant does not leak from the
drain hole under normal operating condifiens,do net replacethe water pump.
If the cooling system is protected by a
coolant inhibitor element (see Figure 22),
the coolant must be tested at required
intervals and the element replaced, if
required. Refer to "Coolant Test
Intervals" chart end "Inhibitor Test
Procedures" under How to Select
Coolant for required test intervalsand
inhibitor levels.Use the coolant e]emant
part number listed in Table 25 in the
Specifications section. The valves
mounted on the adapter head must be
opened after the element isreplaced.
Item 16-
ExhaustSystem
Have the exhaust manifold retaining
bolts and other connectionscheckedfor
tightness. Also have the exhaust pipe
rain cap checked for proper operation, if
so equipped.
36
17 -- Engine(Steam Clean)
It may be necessaryto clean the radiator more frequently if the engine is
being operated in extremely dusty or
dirty areas.
If a Low Coolant Level Sensor is
installedin the top tank of the radiator,it
should be tested for proper operation
every 12 months or 100,000 miles
(160,000 kin), whichever comes first.
Authorized Detroit Diesel distributors
are properly equipped to perform this
service.
Steam clean the engine and engine
compartment every 60,000 miles
(96,000 km) or 2,000 hours, whichever
comesfirst,
NOTICE:
Do not apply steam or solvent directly
on the battery-charging alternator,
starting motor, DDEC components,
sensors, or other electrical components, as damage to elecffrical equipment may result.
Item 19 -- Oil Pressure
Item 18-- Radiator
The exterior of the radiator core should
be inspected every 12 months (300
hours for industrial applications)
or
30,000 miles (48,000 kin) and, if neces
say, cleaned with a quality greasesolvent, such as mineral spirits, and dried
with compressedair. Fueloil, kerosene
or gasoline shouldnot be used.
]
CAUTION:
I
t
To prevent possible injury when /
using compressed air, wear ade-/
quate eye protection and do not /
exceed 40 psi (276 kPa).
j
37
Under normal operation, oil pressure is
notedeach time the engineis started. In
the event the equipment is equipped
with warning lights rather than pressure
indicators, the pressure should be
checked and recorded every 60,000
miles (96,000 km) for vehicle engines or
600 hours for stationary or industrial
engines.
Item 20-- Battery-Charging
Alternator
Terminalsshouldbe checkedfor corrosion and loose connections and wiring
inspectedfor damaged or frayed insulation. Have wiring repairedor replaced,
as Precautions
required.
must be taken when
working on or around the alternator. The
diodes and transistors in the alternator
circuit are very sensitive and can be
easily destroyed.
1. Avoid grounding the output terminal.
Groundingan altemator's output wire
or terminal (which is always hot,
regardless of whether or not the
engine is running) and accidentally
reversing the batte_j polarity will result
in equipment damage,
Item 21 -- Engineand Transmission
Mounts
The engine and transmission mounting
bolts and the condition of the mounting
pads should be checked every 600
hours or 60,000 miles (96,000 km) and
tightenedand/or repairedas necessary.
2. Do not reverse battery connections.
Thiscan alsocause damage.
Item 22-- Crankcase Pressure
The crankcase
_L
A
CAUTION:
pressure
should
be
checked and recorded every600 hours
Or60,000 m!les(96,_ km):
RevVing _ery
pola_ can'aiso"_
result in personal injury caused by
the sudden discharge of electrolyte from the battery vents
and/or t_e sudden rapture of the
battery case caused by explosion
of internal hydrogengas
Item 23
I
Fan Hub
if the fan bearing hub assembly has a
grease fitting, use a hand grease gun
and lubricatethe beatingswith one shot
of MobilgreeseHP, or an equivalentlithium-base multi-purpose grease every
100,000 miles (160,000 km) for vehicle
engines or 1,000 hours for non-vehicle
engines. Care should be taken not to
overfill the housing.
3. Never disconnect the battery while
the alternator is operating. Disconnecting the battery can result in
damage to the alternator diodes. In
applications which have two sets of
Item 24 -- Thermo_tdL_and Seals
batteries, switching from one set to
the other while the engine is running
will momentarily disconnect the batteries. This can result in equipment
damage,
Replace the thermostats
and seals
every 240,000 miles (384,000 km) on
vehicle engines. On non-vehicle engines
replace every 4,000 hours or 24
months, whichevercomes first.
4. If a booster battery isto be used, batteries must be connected correctly
(negative to negative, positive to positive)to avoidequipmentdamage,
Item 25 -- Crankcase Breather
The internally mounted (in the engine
rocker cover) crankcase breather
assembly should be removed every
100,000 to 120,000 miles (160,000 to
192,000 km) (vehicle engines) or every
1,000 hours (non-vehicle engines) and
the steel mesh pad washed in clean fuel
oil.This cleaningperiod may be reduced
or lengthened according to the severity
of service.
5. Never use a fast charger with the batreties connected or as a booster for
battery output.
38
Itenl 26 -- Engine Tune-up
Once the initial measurements/adjust
ments have bean made, any adjustment
beyond this point should be made only
as required to maintain satisfactory
engine performance.
There is no scheduled interval for per
forming an engine tune-up. However,
the valve lash and injector heights on all
Series 60 engines must be measured
and, if necessary, adjusted at the initial
period listed in Table 8.
Engine
Application
Vehicle Engines
Initial Valve Lash
and Injector Height
Measurement/
Adiustment Period
60,000
(96,000miles
kin)
Stationary,
IndustriaJ,or
Marine Engines
or 24 months*
1,500 Hours or
45,000 Miles
(72,000 kin)*
Item 27 --Vibration
Damper
The viscous vibration damper should be
inspected periodically and replaced if
dented or leaking. Heat from normal
engine operation may, over a period of
time, cause the fluid within the viSCous
vibration damper to break down and
lose its dampening properties. For this
reason, the viscous vibration damper
must be replaced at time of normal
major engine overhaul, regardless of
apparent
condition.
*Whichever
comesfirst.
Table 8. ValveLashand InjectorHeight
Adjustment
39
w_ng Preoau_on
A. HOWto Select
NO_C_
LubricatingOil
To prevent damage to the DDEC
electronic control system, discon-
I.ubricant Sele¢li_
in North America
nect battery
power
and ground
The selection oftbeproperlubdcating
oil
cables and the power connector at
is important to achieve the long and
the ECM (electronic control modale)
trouble-free service which Detroit Diesel
before we ding. Failure to isolate
engines are designed to provide. The
the DDEC system from high curproper lubricating oil for all Detroit Diesel
rent flow can result in severe
engines is selected based on SAE visECMdamage.
.....
oosity grade and APt (American
................................................................................ Petro_eem _nstitete)._
desig_at_:_.
"HOW TO" SECTION
Only oils licensed
to display the
American Petroleum Institute (API) symtool shown should be used. See Figure
23.
This section covers Detroit Diesel's recommeedations
on how to select lubricating oil, fuel oil, and coolant and
includes basic engine maintenance procedures which can be performed by the
Lubricant Requirements
The manufacturer's warranty applicable to Series 60 engines provides in
operator.
NOTICE: of such warpart that the provisions
_
ranty shall not apply to any engine unit
that has been subject to misuse, negligenee or accident, Accordingly, malfunctions attributable to neglect or
failure to fol]ow the manufacturer's
fuel
or lubdcating
recommendations
may
not be within the coverage of the war-
_)
SAE ViscosityGrade: 15W-40
API Classification:CH-4
Figure23. API Lubricant ServiceMark
Lubdcants meeting these criteria have
provided maximum engine life when
used in conjunction with specified oil
drain and filter maintenance
schedules.
I ran_.
4O
API OF 4 or CG-4 oils may be used
when CH-4 oils are not available; however, their use may require a reduction
in oil drain interval depending
upon the
application and the fuel sulfur level,
At ambient
temperatures
below
20°C (-4°F) when sufficient
starter
speed cannot be achieved with SAE
15W-40 oils, the use of 5W-XX and
10W-)O( oils, where )0( is 30 or 40, is
allowed to improve startapility, provided
they are API CG-4 and have demonstrated field performance
in DDC
engines. These oils must possess a
HT/HS of 3.7 minimum. Monograde oils
should not be used in Sedes 60 engines
regardless of API Service Class_cation.
The Use of Supplemental Additives
Syntheticoi_
B. When
Synthetic oils may be used in Detroit
Oil Drain Intervals
Diesel engines provided they are API
licensed and meet the performance and
chemical requirements
of non-synthetic
oils outlined
in this
publication,
Synthetic oils offer improved low ternperature flow proper[ies and high ternperature oxidation resistance. However,
they are generally more costly than
non-synthetic oils.
Product information about synthetic
oils should
be reviewed
carefully,
Performance
additive systems often
respond differently in synthetic oils. Their
use does not permit extension of recomrnanded oil drain intervals,
Tllelength oftimean engine may operate
before an oil change depends upon the
lubricant and fuel used, engine oil consumption, and the operating cycle. The
following table lists the _m_ximum interval at which the engine may operate
before the oil and filters must be
changed. Oil analysis may be used to
determine whether this interval should be
shortened, but should not be used to
lengthen the interval.
The use of fuels with sulfur content
above 0.5 mass percent will require a
shortening of drain intervals and/or the
use of a higher TBN oil. See the infermation listed in Table 9. For details refer
to publication
"Engine Requiremants_
Lubricating
Oil, Fuel, and Filters"
(7SE270),
available from authorized
Detroit Diesel Distdbutore.
Lubricants
meeting the Detroit Diesel
specifications
outlined in this publication
already contain
a balanced
additive
treatment.
Supplemental additives are
generally not necessary and can even
be harmful. These additives may be
marketed as either oil treatments
or
engine treatments and are discouraged
from use in Detroit Diesel engines.
Engine damage resulting from the use of
such materials is not covered by your
Detroit Diesel Corporation warranty.
Detroit Diesel will not provide statements
beyond this publication relative to their
use.
41
to Change
Oil
Highway Truck
& Motor Coach#
15,000 Miles
(24,000 kin)
c_
6,000 Miles
(9,600 km) or
3 months,
whichever
comes first
Transit Coach#
C. HOW to Replace the
Lube
Oil
Filters
Fire Fighting
:Apparatus#
6,000 Miles
(9,600 km)
or 300 hours,
whichever
comesfirst
Filters are an integral part of the lubficating oil system. Proper filter selection and
maintenance are important to satisfactory engine operation and service life.
Filters should be used to maintain a
clean system, not to clean up a containinated system. Filter part numbers are
listed in Table 17 in the Specifications
section.
.......
Industrial,
250 hours or
Replace Spin-on Type Oil Filter
Agricultural
1 yr., whichever
comes first
200 hours or
3 months,
whichever
1. Remove the spin-on ltfiers using strap
wrench tool J 29917 (or equivalent)
and a 1/2" drive socket wrench and
extension. See Figure 24.
Stationary Units
Continuous
StationaryUnits
Standby
150hoursor
1 year,
whichever
comes first
#Drain intervals shown apply to pre-1998
model year engines. 1998 and newer
engines may requirea modL_cation
to these
comes first
intervals based on used oil analysis. Refer to
publication,
"Engine RequirementsLubricating Oil, Fuel,and Filters"[7SE270],
available from authorized Detroit Diesel
Distributors.
Table9. MaximumOil Drainand Rlter
ChangeInterval(FuelSulfur 0.5
WeightPercentor Less]
__
Disposing of Waste Oil
Dispose of used Lubricatingoil and fiiters
in an environmentally
responsible
manner, according to federal (EPA} and/or
state recommendations. The disposal of
waste oil may be best addressed by the
engine oil supplier, who may accept
responsibility
for proper disposal of this
material as part of the business of proriding lubricant.
Figure24. Spin-OnOil Filters
42
2. Dispose of the used oil and filters in
an environmentally
responsible manner according to state and/or federal
(EPA)recommendations,
NOTICE:
If the oil levelis constantlyabove normal and excess _ubeoil has not been
added to the crankcase,consult with
an authorized Detroit Diesel service
outlet for the cause. Fuel or coolant
dilution of lube oil can result in serious
engine damage.
3. Clean the filter adapter with a clean,
lint-freecloth,
4. Fill the new filters with clean lubricating oil, and lightly coat the filter
gaskets (seals)with the same oil.
D. Hew
to Select Fuel Oil
5. Start the new filters on the adapter
and tighten by hand until the gaskets
touch the mounting adapter head.
Tighten filters an additional twothirds turn by hand.
Quality--Fuel quality is an important
factor in obtaining satisfactory engine
performance, long engine life, and
acceptable exhaust emission levels.
Detroit Dieselengines are designed to
operate on most diesel fuels marketed
NOllCIE=
today.
In general,fuels meeting the properties of ASTM designation D 975 (grades
1-D and 2-D)haveprovidedsatisfactory
performance.
The fuels used must be clean, completety distilled,stable, and non-eerrosive. For more information regarding the
significance of these properties and
Overtightening may distort or crack
the _lteradapter.
6. Add oil as required to bnng the level
to the "fulF mark on the dipstick,
7. Start and run the engine for a short
selection of the proper fuel, refer to
publication
"Engine Requirements-Lubricating
Oil, Fuel, and Filters"
(7SE270) available from authorized
DetroitDieselDistributors.
period and check for leaks. After any
leaks have been corrected, stop the
engine bng enoL_h for oil from vadous parts of the engine to drain back
to the crankcase (approximately 20
minutes). Add oil as required to bring
the level to the proper mark on the
dipstick.
43
Fuel Contamination--Generally, fuel
contamination
occurs as the result of
improper fuel handling.The most cornmen types of contamination are water,
dirt, and microbialgrowth ("blackslime'S,
The formation of varnishes and gums
resultingfrom poor stabilityor extended
storage ("stale fuel") also affects fuel
quality.The best treatmentfor contamination is prevention by maintaining a
clean storage system and choosing a
reputablefuelsupplier,
.................
......SUpl_en_zLtal..addJti.ves._te..aot
recommended
due to potential
injector system or engine damage,
Our experience has been that such
additivesincreaseoperating costs without providing benefit.
The use of supplemental fuel additives does not necessarily
void the
engine warranty. However, repair
expenses which result from fuel
system or engine component realfunctions or damage attributed to
their use will not be covered. These
products should be accompanied
by
performancedata supportingtheir merit.
It is not the policy of Detroit Diesel
Corporation to test, evaluate,approve,
or endorse such products.
ProhibitedAddibves
The following Fuel Additives are
NOT allowed and MUST NOT be
mixed with diesel fuel:
Used Lubricating Oil--Detroit
Dieselspecificallyprohibitsthe use of
drained lubricating oil in diesel fuel.
Used lubricatingoil contains combustion acids and particulate materials
which can severelyerode fuelin,_"tor
c0mponents _'esulting in loss Of
po_zerand j_c[eased e_baust emissions. In addition,the use of drained
lubricating oi] wiil increase maintenance requirementsdue to filter plugging and combustion depceJts.
Gasoline--
_
CAUTION:
The addition of gasoline to diesel
fuel will create a seriousrite 1=7_rd.
44
CAUTION:
will
reduce fuel cetane
number
Thepresenceof
gasoline
in dieseland
fuel
Diesel fuel is ref,_ively harmless at
increasewhich
combustion
Tanks
contain temperatures.
such mixtures
should be drained and cleaned as
soon as possible.
normal ambient temperatures,
However, when diesel fuel is heated, it may pose certain hazards
which must be guarded agak_'t by
service technicians, engine operatots, andler bystanders,
Detroit Diesel Cerporabon will not be
responsible for any detrimental effects
which it determines
resulted from
adding drained lubricating oil or gasoline
to the diesel fuel.
1. To avoid possible peril
i_,
always keep those not directly
involved in servicing away from
the engine when it is being serviced,
For more detailed information on fuel
selection, refer to "Engine Requirements--Lubricating
Oil, Fuel, and
Filters" (form 7SE270), available from
authorized Detroit Diesel service outlets.
2. The vapors from hot dieeel fuel
may be flammable under certain
E. HOWto Replace the Fuel
conditions.
To avoid possible
personal injury and/or property
damage
from
fire, stop the
engine immediat¢_ if a fuel leak
is detected. This is especially
important if the fuel is cont_
hot fur_
or exhaust system surfaces,
Filters
Eiltersere an integrel pert of the fuel systern. Proper filter selection and maintenance are important to satisfactory
engine operation and service life. Filters
should be used to maintain a clean systern, not to clean up a contaminated
system. Refer to 8peefliealions
(Table
17) for proper filter selection.
Spin-on type primary and eecenda_
fuel filters are used on Series 60
engines. The spin-on type consists of a
shell, element, and gasket unfl#.ed into a
single cartridge and a filter cover which
includes a threaded sleeve to accept the
spin-on filter cartridge. An optional
fueVwater separator may be installed in
pl_ce of the standard
pfimery filter.
3. To avoid a potential fire hazard,
de net allow open flames nearby
or smoke when replacing fuel illters on a hot engine or when
working on an ope_d_,,g engine,
To guard against burns from
direct contact wi_ hot fuel, wear
adequate protective
clothing
(face shield, insulated gloves and
apron, etc.} when performing
either of these eperatlor_,
4. To prev¢_ a buUdup of poteetially volatile vapors from hot fuel,
keep the engine area well vec_-
keeddur_j operafla_
45
Replace Spin-on Type Primary or
Secondary Rlter Elements
5. Thread the new filters onto the
adapters untilthey make full contact
with the gasket and no side movement is evident.Then rotate an additional one-half turn by hand or
tighten per instructionsprinted on the
filter.
t. With the engine shut down, place a
suitablecontainer underthe filter,
2. A fuel shutoff valve may be installed
on the discharge side of the sec*
handle fuel
on the
shutoff
valve turn
to the
ondary
filter,
if _nstalled,
the
closed position (perpendicularto the
valve),
NOTICE:
Overtightening may crack or distort
theadapters.
3. Using a Suitable band Lype. filIer
wrench, remove the primaryand secondary fuel filters. See Figure 25.
Dispose of the filters in an environmen-
6. Turn thetlandle orrthe shutoff valve('it
installed)to the open position (in line
with the valve).
tally responsiblemanner, accordingto
state and/or federal (EPA)recommendations.
7. Start the engineand checkfor leaks.
NOTICE;
4, Fill new replacementfilterswith dean
fuel oil and coat the gaskets lightly
with clean fuel oil.
To improve engine starting, have
replacement filters filled with fuel and
ready to install immediately after used
filters are removed. This will prevent
aeration.
If the engine fails to start after filter
possiblesiphoningand
fuel system
replacement,the
fuel systemwill
require
priming
tool J Diesel
5956 (or
equlvabnt).
AuthorizedwithDetroit
service
outlets
are properly equipped to perform this
service.
NOllCE;
Under no circumstances should the
starting motor and fuel pump be used
I to pnmethe fuel filters.Prolonged use
ofthe startingmotorandfuel pumpto
_rirne the fuel system can result in
damageto the starter,fuel pump, and
injectors and cause erratic running of
I the engine due to the amount of ,airin
the lines and filters.
_gure25. Typic.a]
Spin-OnTypeFuelAlter
46
Replace Fuel/Water Separator
filter element and sealing grommet
assembly, a filter spring, a sea-thru cover
and seal, a cover collar, and a vent cap
and seal. The Fuel Pro 380E system also
includes a fuel heater element, thermostatic switch, and wiring hamess. See
Figure26.
If an optional pnmary filter/water seperator is installed, repb.ce the element as
follows:
1. Drain off some fuel by opening the
drainvalve.
2. Using a strap wrench, remove the
element and bowl together,
then
remove the bowl from the element,
The filter and bowl have standard
1. W'_ the engine shut down and cool,
place a suitable container under the
fuel processor.
right-band threads, so turn counterclockwise to remove,
2. A fuel shutoff valve may be installed
on the discharge side of the fuel filter.
3. Clean the bowl and the O-ring seal.
If installed, turn the handle on the
shutoff valve to the closed position
(perpendicular to the valve).
4. Apply a light coating of clean fuel or
grease to the O-ring seal, spin the
bowl onto the new filter, and b_Thten
COLLAR ...--4_
by h_nd.
To avoid damaging
the bowl or the filNO1_.F.:
[ ter, do not use tools when tightening.
_
CAP,VENT
vf_i
_
ENTCAP
SEAt.
COVER
5. Apply a light coating of clean fuel or
grease to the new O-itng seal on the
top of the filter. Spin the filter and
bowl assembly
onto the filter head,
SSR,._.
FILTER
/...._.<._
SEAL,
and tighten by hand until snug.
ELEMENT,
FILTER
6. To eliminate air from the filter, operate
the primer pump on the filter head (if
equipped) until the fuel purges at the
_
n
7. Start the engine and check for leaks.
Correct any leaks with the engine off.
GROMMET,
FILTERSEAL
FUEL
PROC
Replace "Fuel Pro ® 380/380E"
Filter Element
filterassembly,
Fuel
o_
WIRING HARNESS
The Fuel Pro 380/380E diesel fuel filter
system consists
of a permanently
mounted fuel processor, a replaceable
(38oESYSTEMONLY}
FTgure26. FuelPro 380E FuelProcessor
Assembly
47
3. the
Open
drain valve
the bass
fuelthe
processor,
and atdrain
the fuelof
[r
until it is below the level of the fleer.
Closettle drain valve.Thefuel may be
returnedto the tank.
NOTIC_
/ Do not use a wrench of any kind to
/ tighten the collar, since this may lead
/ to overtightecing which can damage
[ the collarand/or the cover.
4. Using fleer collar wrench 23516731 or
equivalent,remove the collar by turnleg counter-clockwise. Remove the
cover, filter spring, and cover seal ring
by lifting straight up and over the filter
element. Remove the element from
the canter stud (fuet outlet pipe) by
pu_ng u_'_d
_ngrsiightty.
8. Removethe vent plug from the top of
the cover by turningthe plug counterclockwise. RII the cover full of clean
fuel. After making Sure the O-ring seal
is installed on the vent plug, reinstall
th_.pl£gandtighten byhand only"
Currantfilter elementsinclude an integral
NOTE:
sealinggrommet.
Formerfilter elements
used a separate sealing grommet. If a
former element is replaced, make sure
the separate sealing grommet is
removedfrom the centerstud.
I To avoid coverNOTICE:
or vent p_ugdamage,
[ do not use tools to tighten the vent
[ plug.
9. Open the fuel shutoffvalve(ifinsta/led)
and start the engine. When the lubdcation system reaches its normal
operating pressure, increase engine
speed to high idle for 2 to 3 minutes.
5. Disposeof the usedfleerelementand
grommet
in an environmentally
responsible manner, according to
stateand/or federa/(EPA}recommendations.
6. Check to make sure a sealinggrommet is included in the base of the
replacement element, then install the
element onto the canter stud.
NOTICE:
Do not allow the fuel level in the sea I
through cover to fall below the top of
the collar, since this may lead to interruption of the fuel flow and engine
stal ng.
7. Checkto make surethe filter spring is
installed at the top of the cover. If
missing,this spring must be replaced
to insureproper filter operation.Wipe
the cover lip and cover seal clean,
After making sure the seal is property
positioned at the base of the cover,
install the cover and collar onto the
fuel processor. Tighten the collar by
hand untilsecure.
10.After the air is purged and with the
engine still running,loosen the vent
cap. The fuel level in the cover will
start falling.When the fuel levelfalls
to the top of the collar, tighten the
vent cap quicklyby hand.
11. Shut down the engine and hand
tightenthe coJJar
again.
48
NOTICE:
1
I
3. Open
the fuel
shutoff valve
(if
installed).Start
engine,and
check 1II-
Do not use a wrench of any kind to
tighten the collar, since this may lead
to overtighteaing which can damage
the co ar ancVorthe cover,
ters for leaks.
4. If a Fuel Pro 380 filter is installed,
removethe vent plug from the top of
the cover by fuming the plug counterclockwise. Fill the cover full of clean
fuel.After makingsurethe O-ringseal
is installed on the vent plug, reinstall
the plug and tightenby hand only.
12. Restart the engine and check for
leaks,
NO'lIE:
The clear filter cover will not fill completely during engine operation. It will
gradually fill over time, and the fuel level
will rise as the filter medium becomes
clogged. The filter element does not
require changing until the fuel level has
risen to the top of the element, or after
oneyearof service,whichevercomes
first.
NOTICI_
To avoid cover or vent plug damage,
do not use tools to tighten the vent
plug.
I
NOTICE:
I
Do not allow the fuel revel in the see- }
through cover to fall below the top of I
the collar, since this may lead to inter- I
ruption of the fuel flow and engine
stal ng.
F. EngineOut of Fuel---How
to Restart
When an engine has run out of fuel,
there is a definite procedure to follow
when restartingit.
5. Startthe engineand allowthe lubrica-
1. Fill_ fuel tank with the recommended grade of fuel. If only partialfillingis
possible,add a minimumof 10 gallons
(38 liters)of fuel to the tank.
tion system to reach its normal oper
ating pressure,then increaseengine
speedto high idle for 2 to 3 minutes.
After the air is purged end with the
engine still running, loosen the vent
cap onthefilteroover.
The fuel level in
the cover will start falling. When the
fuel levelfalls to the top of the collar
on the Fuel Pro cover, tighten the
vent cap quickly.
2. Close the fuel shutoff
valve (if
installed} and remove the spin-on fuel
filters. Fillwith clean fuel through the
fuel inlet holes (the outer ring of small
holes) to insure the fuel is filtered,
Thread e_erneets onto the adapters
until they make full contact with the
gasket and no side movement is evident. Then rotate an additional onehalf turn by hand or tighten per
instructions
pnnted on the filter.
49
NOTE:
If the engine fails to start after replacement of fuel filters, the fuel system will
require
priming
with
tool
J 5956 (or equivalent). Authorized
Detroit Diesel service outlets are properly equipped to perform this service,
Drop-Out _ Precipitated sludge or
deposit formation in or on cooling systerncomponents.
Fully Formulated Antifreeze -Contains all the necessary inhibitors to
protect a diesel engine, and does not,
therefore, require a pro-charge of SCA
beforeits first use.
NOTICE:
Under no circumstances should th_
startingmotor and fuelpump be used
to primethe fuel filters. Prolongeduse
ofth_ Startingmof0r and fu_t pdmpto
prime the fuel system can result in
damageto the starter,fuel pump, and
injectors and cause erratic running of
the enginedue to the amount of air in
the linesand fillers,
Initial-Fill Coolant -- The coolant that
is used in a new or rebuilt engine, or
any time the cooling system is emptied
and then refilledw_ new coolant.
G. How to Select Coolant
OAT -- Organic Acid Technology. An
inhibitor system based on organic acid
inhibitors instead of traditional North
American inhibitorformuiatioee.
NeAT -- Nitrited Organic Acid
Technology. An inhibitor system based
on nitrite and organic acid inhibitors
instead of traditional Nori.h American
inhibitor formulations.
This section covers selection of the
required coolant for Series 60 engines.
To help ensure more complete understanding of the information, the deflnitions of the following
terms are
provided:
SCA -- Supplemental
Coolant
Additives. (SCAs) are used in a proventire maintenance program to prevent
corrosion, cavitation, and the formation
ofdeposlls.
Antifreeze -- Ethylene GIycol or
Propylene Glycol containing a corrosion
inhibitor package and which meets an
appropriate
heavy-duty
specification
(i.e., TMC RP-329 for ethylene glycol or
TMC RP-330for propyleeeglycol).
Coolant -- The fluid mixturecirculating
in the engine cooling system, t_43ically
a
mixture of 59% water and 50%
antifreeze.
5O
APPROVED
COOLANTS
Ethylene Glycol/Water +
SCA Inhibitor/Propylene
Glycol/Water + SCA Inhibitor
The approved and preferred coolants
for Series 60 engines are listed in Table
10. Once installed, these coolants
should be maintained according to the
procedures
discussed
under
Maintenance.
These products are available as fully
formulated, Phosphate-Free, Extended
Service Interval (ESl) coolants. They are
commercially
available from Detroit
Diesel (recommended)
and other manufacturers, as either a concentrated
antifreeze or as a pre-mixed
antifreeze.
The pre-mixed antifreeze is ready for
use, while the concentrated coolant
must be mixed with water prior to use.
NOTICE:
Required specifications
for water,
ethylene glycol, propylene glycol,
inhibitor packages,
and inhibitor
oentration
are included
in this corn
section. To avoid possible
engine
damage from inadequate or overconcentrated
coolant,
this information should
be read thoroughly
before the coolant is replaced.
Coolant Fill Option
Preduct
EthyleneGlycol&Water+ CorrosionInhibitors1
DDCPower Cool
CommercialEquivalentof DDCPower Cool
FullyFormulatedTMCRP-329Type A
Ant_eeze _Water
Propylene Glycol & Water
+ Car(asianInhibitors
FullyFormulatedTMC RP-330 Type
A Ant#eeze &Water
EthyleneGlycol&Water+ NeAT Inhibitors
DDCPower Cool Plus
Water Only+ Corrosion_nhibitors
2
Water+ DDCPower Cool3000
WaterOnly + NeAT Inhibitors2
Water+ DDCPower Cod Plus6000
1Preferred Coolant
2Water-only
coolantsystemsoffernofreezeprotect_3n
andshc_ldnotbe usedwhereambient
temperatures
c_n fall to 32°F (0°CI.
Table 10.InitialFillCoolant Options
51
Detroit Diesel Power Cool Engine
Coolant (P/N 23512138) is the preferred ethylene glycol coolant, if other
commercial brands of ethylene glycol
are used, they must be equivalent to
the Power Cool (see next paragraph),
Detroit Diesel does not market a propylene glycol coolant, if a propyleneglycol
coolant is used, it must also meet the
requirementslisted below,
Fully formulated
ethylene glycolbased, low silicateantifreezeor coolant
must meet TMC RP_329 "Type A7
requirements: Fully ,formulated propy......
lene glycol-based antifreezeor coolant
must meet TMC RP-330 "Type A"
requirements.
Fully formulated
antifreezedoes not requirea dosage of
SCA prior to initial use,
Mixing EG er P6 A,-_ii[ieeze
and Water
If a concentrated EthyleneGlycol (EG)or
Propylene Glycol (PG) antifreeze is purchased, mix the antifreeze with water
meeting the required quality standards
listed in Table 13 and itll the cooling system.
Fully Formulated
If a pre-diluted, fully formulated
coolant is purchased,simplyfill the cooling system. For best overall perfor
mance, a coolant consisting of 50%
concentration
of antifreeze
(50%
antifreeze,50% water) is recommended.
An antifreeze concentration over 67%
(67% antifreeze,33% water) is not recommended due to poor heat transfer,
reducedfreeze protection(lEGonly),and
possible silicate dropout. An antifreeze
concentratioq
bet0w 33% (33%
antifreeze, 66% Water) offers too Ittle
freeze_e_ c.orres_qprotestienand _s
not recommended. See Figure 27 for
ethylene glycol-based coolant coneentratiee versus freezing and boiling ternperatures.See Figure28 for propylene
glycol-based coolant concentration versus freezing and boiling temperatures.
Always verify that the freeze point and
nitrite concentration of the antifreeze/
water mix are correct by using a
PowerTracTM 3-Way CoolantTest Strip.
If chemical analysis is used, elements in
the coolant must fall within the limits listed in Table 11.
Glycol Coolant Concentration
Boron
125- 500PPM
Nitrite
800- 2400PPM
Nitrate
200- 750PPM
Silicon
50- 250PPM
Phosphate
0 PPMMax.
pH
8.0 - 10.5
Limits
Table11.FullyFormulated
GtycolCoolanttJmffswithTMCRl3-329,RP330Chemistry
TypeA
(50/50CoolardWater
Mixture)
52
COOLANT
FREEZING
AND BOIUNG
TEMpERA_RES
VS. lEG
CONCENTRATION
(S_s.
LEVEl
320
I
PROPYLENE
GLYCOL
IPGBoilingPoint
160
,2,
112_.
•
.°
E
o
6o
49
IPG Freezing Point
39
27
16
4
-lg
c°_
_°"
t=_,
0
10
20 30
40
lEG CONC_NTRA_ON
=7
40
62
ss
s_
Temperaturesvs.Inhibited
PropyleneGlycol(IPG)
Figure28. CoolantFreeing and Boiling
ConcentfatJbn(SeaLevel)
60 70 80 90100 TM
Ethylene Glycol / Water + NOAT
Inhibitor
{% BY VOLUME)
Figure27. CoolantFreeing and Boiling
Temperaturesvs.Inhibited
EbhyleneGlycol(lEG)
Propyiene Glycol / Water + NOAT
inhibitor
Concentration(SeaLevel)
Ethylene glycol and propylene glycol
are also available with a Nitrited Organic
Acid Technology
(NOAT) corrosion
Recycled Antifreeze
Antifreeze or coolant
recycled by
reverse osmosis, distillation, and ion
exchange, property re-inhibited
to meet
TMC RP-329TypeAor
RP-330TypeA
requirements has been demonstrated
to provide service equivalent to virgin
antifreeze. Recycled antifreeze or
coolants of these types are preferred,
Other recycled coolants, especially
coolants recycled through filtration pro_,
are not recommended,
inhibitor package. These coolants
require less maintenance over the useful life of the engine. NOAT coolants,
maintained
as detailed
in the
Maintenance section, may be operated
up to 4 years, 600,000 miles, {960,000
kin), or 10,000 operating
hours,
whichever comes first. The cooling
system should either be equipped with
a "blank" coolant filter or the coolant fllter and piping may be omitted from the
system.
53
NOATfully formulatedantf[reezesare
available as concentrated and premixed. Concentratedantifreezesshould
be mixed at 50% (50% antifreeze/50%
water). NOAT coolants should not be
mixed with conventional coolants. If
they are mixed, no damage will result,
but the long-life advantages of the
NOAT coolant will be lost. In this event,
the coolant should be maintained as a
fully formulated EGI coolant, not as an
OATcoolant.
Detroit Diesel markets a NOAT inhibit,d ethylene glycol coolant; DDC
Power Cool Plus.Power Cool Pluscontains all of the required additives. If a
non-DDC NOAT antifreeze is used, it
must conform to TMC 338 specitication. Do not add extender to new NQAT
anti#eezeor coolant,
dosage of corrosion inhibitore. Detroit
Diesel-approvedSCAs or NOAT oorrosion inhibiters must be added to the
water to providerequired corrosionand
cavitation erosion protection. NOAT
inhibitors such as Power Cool Plus
6000 are available for water-only systems. Inhibitorshouldbe mixed at 7.5%
(pending)by volume with water. Power
Cool products are listed in Tables 19
thru 28. Traditional SCA (Power Cool
3000) can also be used to protect the
engine. Power_3t 3000 c_,oelantconcenttafion limitsare'ltstedin Table 12:
NOTE:
Do not use Power Trac 3-Way Test
Strips to test NOATcoolant.
Power Cool 3000 SCA inhibitors
should be mixed at 5% by volume Wnth
water. This is 1 quart per 5 gallons of
water.These additions can be made by
adding liquid SCAs availablein a variety
of sizes.Coolantfittersare also available
for different cooling system capacities.
These filters release the proper amount
Water Only+ SCA
Water Only + NOAT Inhibitor
In warm climates a coolant based on
water with corrosion
inhibitors
is
approved for use. Water-only systems
need to be treated with the proper
of SCA at initial fill.
Power Cool 3000 Coolant Conce_l='atiooUmits
Boron
125- 500PPM
Nitrite
800- 2400PPM
Nitrate
0- 750PPM
Silicon
50- 400PPM
Phosphate
0 PPMMax.
pH
8.0- 11.0
Table12.PowerCool3000Concen#ation
Limits_5%PowerCool3000/95%Water)
54
Water Requirements"
COOLANTS NOT RECOMMENDED
Distilled, reverse
osmosiseliminates
purified, the
or
de-ionized
water which
adverse effects of minerals in tap water
The following coolants are not recom-
is preferred. High levels of dissolved
chlorides, sulfates, magnesium, and
calcium in some tap water causes scale
deposits, sludge deposits and/or corrosion. Those deposits been shown to
result in water pump failures and poor
heat transfer, resulting in over-heating.
If
1. All antifreezes and coolants conraining phosphate should be avoided. Drop out, overheating, and water
pump sea] failures can result from use
of coolant or inhibitor packages
based on phosphate.
tap
used,
mineral
the water
water is
must
bethe
below
the content
maximumin
2. Automotive type coolants generally
contain high levels of phosphate and
silicate, offer no liner pitting protec-
allowable
mended for use in Series 60 engines:
limits listed in Table 13.
Maximum Allowable
Parts
)er Million
Grains
per Gallon
Chlorides
40*
2.5
Sulfates
100"
5.8
Total
Solids Dissolved
Total Hardness
Magnesium
&Calcium
340
20
170
10
tion, and are not suitable for use in
Detroit Diesel engines.
3. Methyl alcohol-based
antifreeze
must not be used because of its
effect on the non-metallic components of the cooling system and its
low boiling point.
4. Methoxy propanol-based
antifreeze must not be used because it
is not compatible with fluoroelestomer
sealsfound in the cooling system.
Limits CurrentlyUnder Review
5. Glycol-based
Table 13. SatisfactoryWaterLimits
coolants formulated
for heating/ventilation/air
conditioning (HVAC) should not be used.
These coolants generally contain high
deposit on hot internal engine surfaces
heat transfer.
levels and
of reduce
phosphates,
which can
Do not add additional SCA to new, t
fully formulated antifreeze or coolant. |
This can result in dropout and/or the /
formation of deposits.
J
55
AJDD_
NOT RECOMMENDED
If topping off is needed, add coolant
which is identical to the initial flu coolant.
The following additives are not recommended for use in Series 60 engines:
.....
Supplemental Coolant Additives for
Fully Formulated Coolant
1.Soluble
oil additives
ere not
The concentrations of some inhibitors
approved
for use in Detroit Diesel
will gradually
deplete during normal
engine cooling
systems.
A small
engine operation. SCAs replenish the
amount of oil adversely affects heat
protection for cooling system compotransfer. For example, a 1.25% connents. The coolant must be maintained
cantration of soluble oil increases the
with the proper concentration of SCA.
fire deck t#mpereture 6%. A 2.50%
Detroit Diesel Power Cool maintenance
concentration iedrease_ the fire desk
SCAs are reeommended_The
proper
temperatur, a 15%. _qe use of solubJe.........application of SCA _ill'p_-oqide:.............
oil additives may result in engine overhosting and/or failure.
• pH control.
• Restored
inhibitor
corrosion.
2. Chromate
additives
are not
approved for use in Detroit Diesel
engine cooling systems. Chromate
additives can form chromium hydrex-
levels
to prevent
• Water-soffening to deter formation of
mineral deposfLs.
ide, commonly
called "green slime."
This, in turn, can result in engine damage due to poor heat transfer. Cooling
systems operated
with chromateinhibited coolant must be chemically
c]osned with Power Cool Dry Chemical cooling system closner/conditioner
(or equivalent sulfemic acid/sodium
carbonate cleaner) and flushed,
• Cavitation protection
sleeve cylinder liners.
to protect
wet
NOTICE:
Failure to properly maintain coolant
Wrth SCA can result in damage to the
cooling system and its related components. Conversely, over-concentration
of SCA inhibitor can result in poor heat
transfer, leading to engine damage.
Always maintain
concentrations
at
recommended levels. Do not use tra
MAINTENANCE
TopPing Off Coolant
Coolant level should de checked at the
maintenance intervals listed in Table 14.
ditional SCAs with NOATcoolant.
ServiceApplication
InhibitorTest Interval
On HighwayTrucks and Motor Coaches
15,000 Mi_s (24,000Kilometers)
City Transit Coaches, Pick-up and Delivery
ShortTrip, andEmergencyVehicles
6,000 Miles (9,600 Kilometers) or three
months,whichevercomesfirst
Industrial,GeneratorSet,
and al; Other Applications
200 Hoursor year]y,whichevercomesfirst
Table14. RequiredCoolantInhibitorTestIntervals
56
Check the nitrite concentration at the
regular intervals listed in Table 15 with a
PowerTrac 3-Way Test Strip. Nitrite levels must be within the ranges listed in
Table 1 1. Additional
SCA must be
added to the coolant when it becomes
depleted, as indicated by a nitrite conCoolant
Antifreeze/Water+ SCA
InhilEiter{DDCPower Cool)
centration of 800 PPM or less. If the
nitre concentration is greater than 800
PPM, do not add additional SCA. If the
nitdte concentration is above 2400 PPM,
the system is over-inhibited and should
be partially drained and filled with a
50/50 mix ofwater and EG or PG.
IntervalI
At'lion
A 20,000 miles,(32,000 kin),
or 3 mos.
B 500 hoursor 3 mos.
Testnitriteconcerrbation
with test strip.Add SCA or
dilute coolantas needed.
Engine overhaul. Refer to
engineservicemanual.
Drain and deen system.
Replacew/new coolant.
EthyleneGiyoolRVater+
SCA Inhibitor
or
PropyleneGlycolRVater+
SCAInhibiter
A 20,0gOmiles,(32,000 kin),
or3 mce.
B 500 hoursor 3 mos.
Engineoverhaul.
Testnitriteconcentration
withtest strip.AddSCA
dilutecoolantas needed.
Drainand cleansystem.
Replace
w/newcoolant.
EthyleneGlycoWVater+
NOATInhibitor
or
PropylaneGlycol/Water+
NOATInhibitor
A 300,000 miles,(480,C00kin),
or 2 yrs.
B 5,C00hours
A 600,0COmiles,(960,000 kin)
B 4 years,or 10,000hours
Add PowerCool plus
Extender
WaterOnly+ SCA Inhibitor
A 20,000 miles,(32,000 krn),
or 3 mos.
B 500 hoursor 3 mos.
Engineoverhaul
Test nitriteconcentration
with te_ s-hip.Add SCA or
dilutecoolantas needed.
Drainandclean system.
Replacew/new coolant.
Wateronly + NOATInhibitor
A 300,000 miles,(480,000krn),
or2 yrs.
B 5,000 hours
A 600,000 miles,(960,000kin)
B 4 years,or 10,000hours
Add Power CoolPlus
Extender
Drainand clean system.
Replacew/new coolant.
Drainand clean system.
Replacew/new coolant
1 MaJntenance
intervalbasedonapplication.DrainintervaJ
dependenton propermaintenance.
A. OnHighwayTrucksandMotorCoaches,CityTransitCoaches,PickupandDelivery,
ShortTrip,and
Emergency
Vehicles
B. Inpestfial,Marine,Generator
Set,andotherapplications
Table 15. CoolantMaintenanceIntervals
57
In this case the EG or PG shouldcontain no inhibitors, and should conform to
ASTM D4985. This will dilute the overconcentrated inhibitors.
4. Color change of additive indicator
(middle pad) indicates presence of
inhibitor that is not approved by
Detroit Diesel.
NOTE:
In non-NOAT systems, nitrite concentration of 3000 PPM or higher on a Series
60 enginesuggests problematicadditive
ovar-concentration.This condition must
be corrected by immediatedrainingand
flushingof the cooling system. Refillthe
system with new fully formulatedor prechargedcoolant. Check thernttritecoNcantration levee at the next maintenance
interval with a PowerTrac 3-Way Test
Stnp.
For best resultsmake the tests while
the coolant is between 50 ° - 140°F
(10.0° - 60°C). Wait at least60, but not
longer than 75, seconds beforereading
the nitrite level. Promptly replace and
tighten the test stnp containercap after
eaelquse. Discard unused strips if they
haveturned light pink or tan.
A factory bc_lant analysisprogramiS
available through authorized
Detroit
Diesel serviceoutlets, Referto Table 28
in the Specification
sectionfor partnumbers. To verifycoolant acceptability,submit a sample for coolant analysisevery
SCA TEST PROCEDURES
Detroit
Diesel PowerTrac
3-Way
three (3) years,300,000 miles,(480,000
kin), or 6,000 operating hours, whichevar comes first.
Coolant Test Strips should be used to
measure nitrite and glycol concentrations. Refer to "Power Cool Engine
Products"
section for part numbers.
Cavitation/corrosion protection is indicared on the strip by the level of nitrite
concentration. Freeze/boil-overprotec
tion is determined by glycol concentration. Use the test strips as follows:
NEED RELEJk.qE
FILI'm_8 INON-NOAT SYSTEMS)
Spin-on coolant filters are available for
Detroit Diesel engines. Membranes in
the filters release SCAs before the
coolant approaches a corrosive condi-
1. Dip the strip into coolant for one sec
tion,
the engine
sion. protecting
The elements
releasefromthe corroSCA
charge as needed, as opposed to the
maintenance SCA elements, which
instantaneously release the SCA charge.
These elements should be replaced
after 1 year, 120,000 miles, (192,000
kin), or 2,000 operating hours, whicbever comes first.
ond.
eliminateRemove
excess and
fluid.shake briskly to
2. Immediately compare end pad (%
Glycol) to the color chart on the container,
3. Sixty seconds (one minute) after dipping, compare the nitrite pad to the
color chart.
58
DROPOUT
The proper application of extender to
Excessive amounts of some inhibitors
in the engine coolant can cause a gel or
crystalline deposit that reduces heat
transfer and coolant flow. The deposit,
called "dropout," takes the color of the
coolant when wet, but appears as a
white or gray powder when dry. It can
pick up solid particles in the coolant
NOAT coolant will provide:
• pH control.
• Restored inhibitor levels to prevent
corrosion
• Cavitation protection to protect wet
sleeve cylinder liners
NOTE:
Do not use traditional
SCAs in
and become gritty, causing excessive
wear of water pump seals and other
cooling system components. The wet
gel can be removed by using a nonacid (alkali) type heavy duty cleaner
such as Detroit DieselPower Cool OnLine Cleaner (sodium nitrite/sodium
tetraborate). Refer to "Power Cool
NOAT coolant,
not use
NOAT
extender and
in do
traditional
coolants.
NOAT Coolant Drain Interval
A properly maintained NOAT-inhibited
coolant willlast 4 years, 600,000 miles,
(960,000 km), or 10,000 operating
hours, whichever comes first. At this
time the coolant should be drained, and
EngineProducts" section for part numbets. If the gel is allowed to dry, it is
necessary to disassemble the engine
and clean it with a caustic solution or
physically clean individual components,
the cooling system should be thoroughly cleaned,flushed,and filled with new,
properlyinhibited NOATcoolant.
EXTENDER INHIBITOR
ADDrrlVE FOR =NOAT"
CHRONIC COOLANT SYSTEM
PROBLEMS
COOLANT
The inhlbitors in NOAT coolant must
also be maintained, but less often than
traditional SCA-type coolants. A
portable test is available to test the levels of NOAT inhibitors in coolant. Where
this is not used, fleet testing has deter
mined that a NOAT coolant extender
package should be added to the
coolant at 300,000 miles, (480,000 kin),
2 years, or 5,000 hours, whichever
comes first. The proper maintenance
dosages for all NOAT coolants are listed in Table 14, reflecting 0.6% by volume extender. This dosage should be
added to the water-only and the glycol
systems at the same interval.
7he most commonly seen coolant system problems result from maintenance
and formulation factors such as:
1. HardWater
2. Dilution of the Coolant by the eddition of Untreated Water.
3. Over or Under Dosage of Corrosion
Inhibitors
4. Improper Corrosion
often Phosphated)
5. Mixing SCAs
6. ImproperTesting
59
Inhibitor
(most
DETROIT DIESEL COOLING SYSTEM MAINTENANCE PRODUCTS
Summary of Coolant
Recommenda_ons
Power Cool SCAs are water-soluble
chemical compounds. These products
are availablein coolant filler elements,
liquid packages, and in fully formulated
Power Cool antifreeze.
NOTE:
Power Cool 3000 liquid SCA is more
compatible with hard water than
Power Co_2000SCAL
........ ..: ..............
Power CooLCoolant.Fdter Elements
(spin-ee canisters)are availablein various sizes suitable for cooling systems
of varying capacity. Selection of the
proper eleme_t size is vital when pre-
_1_
CAUTION:
To avoid possible personal injury
(scalding, eye injury) from the hot
coolant, never remove the cooling
system fill (pressure) cap while
coolant is hot The system may be
under pressure. Remove the cap
sJow/y anti only when coolant is at
ambient,.te;
...............................
1. Always maintain the engine coolant
to rr_-=tDetroitDie.setspes_cat_ons.
charging non-fully formulated coolant
(i.e. water) at initial fill and at maintenance intervals.
A fully formulated
antifreezemust NOT have SCA added
at initial fie Do not use SCA-containing
fillers with NOAT antifreezeor coolant.
The need for maintenanceelements is
determined by the results of the nitrite
concentration test performed at each
cooling system service interval.Do not
automatically install maintenance elements at maintenanceintervals unless
the nitrite concentrationlevel fallsbelow
800 parts per million,
2. Onlyuse waterthat meetsthe specifications listed in Table 13. Distilled,
de-mineralized(reverseosmosis) or
de-ionized water is preferred.
3. The proper dosage of inhibitors
must be included in the coolant at
initial fill for all Detroit Diesel engines.
This dosage is usually included in
the fully formulatedantifreezeused,
or it may need to be added if water
alone or if less than 50% ant#eeze
is used. The user is urged to referto
the full text of this section to deter
mine the proper dosage. Mixing of
different manufacturers' technologies (brands) coaid cause cooling
systemproblems.
Power Cool Liquid On-Line Cleaner
is used for light deposits. Power Cool
Dry Chemical Cleaner/Conditioner
is used for heaw deposits or scale.
60
4. Maintain the inhibitor at the prescribed concentration.
Test the
nitrite concentrationby using a titration kit or Detroit Diesel PowerTrac
10. Coolant Ufe:
• Glycol Coolant. A properly maintained cooling system, filled with
phosphate-flee
coolant consisting
of a 50/50 mix of antifreeze and
water per TMC RP-329 'q-ype A" or
TMC RP-330 "Type A" can be
3-Way Coolant Test Strips. Add
SCA oely if the nitrite concentration
is below800 PPM. Do not useSCA
in NOAT coolant, and do not use
PowerTrac3-Way TestStrips to test
NOATcoolant.
operated for the life of the engine,
until overhaul The proper maintenance involves periodic evaluation
using PowerTrac3-Way Test Strips
and addition of SCA as needed,
NOTE:
If the nitrite concentration exceeds
2,400 PPM, the coolant must be
indicated by the strip test. To verify
coolant acceptability, submit a sampie for coolant analysisevery three
(3)years, 300,000 miles, (480,000
kin), or 5,000 operating hours,
whichevercomes first. Submitthe
sample in DDC PowerTras Coolant
Test Bottle. Refer to Table 28 in
"PowerCool EngineProducts"sec-
drainedand replacedwith new coolant,
A thorough cleaningof the cooling systern may be required,
5. Do not use another manufacturer's
test kit to measurethe SCA concentration of DefroitDieselMaintenance
Products.
6. Premix coolant makeup solutions to
the proper concentration
before
adding to the cooling system.
7. Do not mix NOAT and other
coolantsin the .sameengine.
8. Do not use automotive coolants or
coolants with phosphates.
tion for part numbers.
g. Where antifreeze/boil over protection is required, use only antifreeze
that meets TMC RP-329 (EG)'_ype
A" or TMC RP-330 (PG) "type A"
specifications.
Always maintain
coolant at the proper level.
61
• NOAT Coolant. A properly main-
H. HOW to Drain and Flush
rained
coolant
may
be
operatedNOAT
4 years,
600,000
miles
(960,000 km), or until overhaul,
whichever comes first. At this time,
the system must be completely
drained, thoroughly cleaned, and
refilled,
the Cooling System
A
Do not remove the pressure control cap from the radiator or
attempt to drain the coolant until
the engine has cooled. Once the
engine has cooled, use extreme
care when removing the cap. The I
sudden releaseof-pressure fn_n a I
heated"c_oling'sYstemcanresultii_' 1........
a loss of coolant and possibleper-
• NOAT Coolants require the addition of an extender at 2 years,
300,000 miles, (480,000 km), or
5_000 hours, whichever comes
..... first. Use 1 pint of extender for
every20 gallonsof coolant,
• Other properly
maintained
coolants may be operated up to 2
years, 250,000 miles, (400,000
kin), or 4,000 operating hours,
whichever comes first. At that
time, the system must be completely drained, thoroughly
cleaned, and refilled,
liquid. injmy (scalding}from the hot
sonal
1. With the enginecool, drainthe previous solution from the engine and
radiator. Dispose of the solution in
an environmentallyresponsiblemanner accordingto state and/or federal
(EPA) recommendations.
11. Do not use the following in Detroit
Dieselenginecooling systems:
2. Refillthe cooling system with clean,
soft water and a good cooling systern cleaningcompound, such as
those listed in Table27. If the engine
• Solubleoil
• High silicate,
antifreeze
automotive
CAUTION:
type
is warm, fill slowly to prevent the
rapid cooling and distortion of the
metal castings.
• Chromate SCA's
• Methoxy propBP, ol-base cocYant
3. Start the engine and operate it for fifteen minutesto circulatethe solution
thoroughly.
• Methylalcohol-basecoolant
4. Stop the engineand allowit to cool.
• Sealer additives or coolant
raining sealer additives
con-
5. Wr_h the engine cool, drain the cooling system completely.
6. Refill the cooling system with clean,
soft water and operate it for f_een
minutes.
• HVACcoolant
• Phosphated
coolants
62
7. Stop the engineand allowit to cool.
NOTE:
If Detroit DieselPower Coo/antifreeze/
coolant (or equivalent fully formulated,
precharged antifreeze) is used, a
precharge element is not required.
Coolant inhibitorlevelsmust be checked
at the intervals listed in Table 14.
8. With the engine cool, drain the
cleaner residue from the cooling
system,
9. Refill the system with the required
coolant.Referto SectionG.
I. When to Servicethe Dry
TypeAir Cleaner
10. Entrabpedair must be purged after
fillingthe cooling system.To do this,
allow the engine to warm-up without
the pressure cap installed. With the
transmission
in neutral, increase
engine speed above 1000 RPM and
add coolant as required,
NOTICE:
Replace dry type air cleaner elements
when the maximum allowable air cleaner restriction (20 inches of water or 5.0
kPa) has been reached, or annually,
whichever comes first. Some air cleaners are equipped with a restriction indicator which aids in determining the
servicinginterval.
Cleaning and/or reusing dry paper
type air cleaner elements is not recom-
If the engine overheats and the
coolant level is satisfactory, the cooling system may require cleaning with
mended unless the cleaning method
used removesclogging withoutdamage
to
element.must
Inspection
of the
elements
be doneandincleaning
aceor-
a deecaling solvent and beckflushing,
Authorized
Detroit Diesel service out-,
lets are properly equipped to perform i
these services.
dance with the air cleaner manufactur-
Install
the pressure
cap after the
coolant level has stabilized at the bottom of the radiatorfillerneck.
er's recommendations,f any.
In addition to the cleaning procedure,
other components of the cooling system
should be checked benodically to keep
the eoghqe eperating at peak ef_c_lcy.
Cooling system _
should be
inspected and any heee that shows obvicos signs of _
or feels_ly
soft ar hard sbeuld be repleced. Damaged
clamps should be replaced. All extemai
leaks should be corrected as soon as
detected.
63
BASIC TROUBLESHOOTING
HARD
STARTING
Engine Will Not Rotate
Probable Causes:
Low Cranking Speed
[
Low battery voltage
Loose cranking motor
.......
X
X
connections
X
Faufbjcrankingmotor
Faultycranking motor switch
X
Internal dei2di_........................................
X
improper
lubeoil
Circuit breaker/electroniccontrol
malfunction
Fuse
blown
ormissing
X
X
Insufficient
Engine Cranks But Will Not
Stal
X
X
X
X
Fuel Supply
Air in fuel
Outoffuel
Loose
fuel
connections
Cracked
fuel
lines
Obstructed
fuel
filters/lines
Faulty
fuel
pump
Faulty
injector
operation
Restricted
fuel
fitting
missing
DDECmalfunction
Installation/operation
offuel
check
valve
orshut-off
valve
X
X
X
X
X
X
X
X
X
X
Low Compression
Worn intake and exhaustvalves
Worn piston tings/liners
Leakingcylinderhead gasket
Improper intake and exhaust
X
X
X
valveadjustments
IX
64
OBJECTIONABLE
EXHAUST
Black or Gray Smoke
Probable Causes:
Blue Smoke
White Smoke
Damaged or dirty air cleaner
improper grade of fuel
Excessive exhaust back pressure
Misfiring
cylinders
Lubricating
oil not burned in
cylinder (being burned in
exhaust manifold or turbeaharger)
Faultyinjector setting
Faultyoil controlrings
Excessive instai_ationangle
Excessiveoil in crankcase
X
X
X
High ambient air temperature
Thinair (highait_ude)
Cetaneratingof fueltoo low
Airin thefuelsystem
X
X
ABNORMAL
X
X
X
X
X
X
X
X
ENGINE OPERATION
Rough
Probable Causes:
Running
or Frequent
Low Power
Detonation
Misfiring cylinder
Insufficient
fuel
High return fuel temperature
Lowcompression
DDECmalfunction
High air inlet restriction/exhaust
backpressure
Engineapplication
High air inlet temperature
Highaltitudeoperation
Incorrect engine gear train timing
Lowcoolanttemperature
Oil picked up by inletairs'Cream
Faultyinjectoroperation
Incorrect injector height setting
X
X
X
X
X
X
X
X
X
X
I
X
X
X
X
X
X
65
X
X
X
X
Stalling
ABNORMAL
OPERATING CONDITIONS
High Lubricating
Probable Causes:
Oil Consumption
Low Oil Pressure
Looseconnections
Cracked
lines
Damaged gaskets or seal rings
*Lube oil loss at breather tube
*Lube oil loss at dipstick tube
X
X
X
X
X
*indicateshigh crankcase pressD[e
.............
Leaking
oilcooler
Leakingvalvestemseals
Worn/broken oil control rings
Scored liner and/or piston
Excessive engine installation angle
Crankcase overfilled
Oil in air tanks (air compressor
maffunction)
Plugged crankcase breather
Oillevel
low
Improper engine oil viscosity
(fuel
intheoil)
Faulty oil pressure regulator valve
Worncrankshaftbearings
Worn camshaft or connecting rod
beatings
Missing cup plugs in rocker arm
shafts
Faulty oil pressure reliefvalve
Air leaks in oil pump (suction
side)
Wornor damagedoilpump
Faultyoil pressuregage
Faulty electrical components
(for
gage)
Plugged
oilorifice
Obstructed
oilline
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
66
ABNORMAL COOLANT TEMPERATURES
Above Normal
Probable Causes:
Below Normal
Restricted cooling system
passages
Restrictedradiatorcore passages
Slippingfan drivebelts
Faultytemperature-controlredfan
Obstruction in front of radiator or
intercooler
Lowcoolantlevel
Damaged
hoses
Faultythermostats
Faultywaterpump
Faulty radiator pressure cap
Air in coolant
Thermostatsnot fullyclosed
Leakage around thermostat seals
Faulty temperature-controlled fan
X
X
X
X
X
X
X
X
X
X
X
X
x
X
67
ENGINE STORAGE
5. if #eezing weather is expected during
the storage
period,
check
the
antifreeze/coolant for required freeze
Preparing Engine for Storage
When an engine is to be stored or
and inhibitor
protection.
Add
removed from operation for a period of
antifreeze solution to the cooling systime, special precautions
should be
tem in accordance with the manufactaken to protect the interior and extedor
turer's recommendations.
of the engine, transmission
and other
parts from rust accumulation and corroNOTE:
sign. The parts requiring attention and
If an antifreeze solution is not required
the recommended
preparations
are
during storage, flush the cooling system
givenbelow,
with a good solubleoil (3%-5% by vol.....................
ume) rust inhibitor to prevent rusting of
it W_!be n_ar_
t? remoye all rust.....
.
.
.
.
or corrosion
completely
from any
the
outside
diameter
of
the
cylinder
Irners.
exposed part before applying rust preventive compound. Therefore, it is recommended
that the engine
be
6. Clean the exterior of the engine
processed for storage as soon as possi(except electrical components)
with
ble after removal from operation,
fuel oil and dry with compressed air.
engine should be stored in a buildJb,
ing that is dry and can be heated during
_
CAUTION:
the winter months. Moisture absorbing
chemicals are available commercially for
To prevent possible personal inuse when excessive dampness prevails
jury when using compressed air,
inthe storage area.
wear adequate eye protection and
do not exceed 40 psi (276 kPa) air
Temporary Storage
(30 Days or Less)
_ressure.
To protect an engine for a temporary
period of time, proceed as follows:
7. Seal all engine openings. The material
used must be waterproof, vaporproof
and possess
sufficient
physical
strength to resist puncture and damage from the expansion of entrapped
air.
1. Drain the engine crankcase,
2. Fill the crankcase to the proper level
with the recommended
viscosity and
grade of oil.
An engine prepared in this manner can
be returned to service in a short time by
removing the seals at the engine openings and by checking
the engine
coolant, fuel oil, lubricating oil and transmission oil levels.
3. Fill the fuel tank with the recommended grade of fuel oil. Operate the
engine for two minutes at 1200 rpm
and no load. Do net drain the fuel
system or the crankcase after this
run,
4. Cheek the air cleaner and service it, if
necessary.
68
Extended Storage
(More than 30 Days)
NOTE:
If engines in vehicles are stored where
condensation of water in the fuel tank
may be a problem, additivescontaining
Methyl Carbitol or Butyl Cellusolvemay
be added to the fuel. Followmanufacturer's instructions for treatment. Where
biological contamination of fuel may be a
problem, add a biocide such as Biobor _
JF(or equivalent)tothe fuel.When using
a biocide,follow the menufacfurer'sconcentration
recommendations,
and
observeallcautionsand warnings.
To prepare an enginefor extendedstorage (more than 30 days), follow this
procedure:
1. Drain the cooling system and flush
with clean, soft water. Refill with
clean, soft water and add a rust
inhibitorto the coolingsystem,
2. Circulatethe coolant by operatingthe
engine until normal operating temperatureis reached.
7. Drain the fuel system and remove
the fuelfilters.Disposeof usedflltere
in an environmentally responsible
manner, according to state and/or
federal (EPA)recommendations.Fill
new filterswith No. 1 dieselfuel or
pure kerosene, and reinstall on the
engine.
3. Stop the engine,
4. Drain the engine crankcase, then
reinstall and tighten the 3/4"-14
square, magnetic oil drain plug to 4550 Nora (33-37 Ib ft) torque. Install
new lubricating oil filters.
5. Fillthe crankcaseto the proper level
8. Operate
the engine
minutes
to circulate
the for
cleanfivefuel
oil
Tectyl® 930A preservativelubricating oil or an equivalent 30-weight
preservative lubricating oil meeting
MiI-L-21260C,Grade2 specification,
throughout the engine. Be sure the
engine fuel system is full Disconnect
the fuel return line and the inlet line
at the primaryfilter and securelyplug
6. Drainthe fuel tank. Refillwith enough
clean No. 1 diesel fuel or pure
kerosene to permit the engine to
operate for about ten minutes. If
draining the fuel tank is not conveniant, usea separate,portablesupply
of recommended fuel.
both to retainthe fuel in the engine.
9. Servloe the air cleaner.
10.Transmission--Follow the manufacturer's recommendations for prolonged storage.
69
1t. Power Take-Off-- (If equipped)_
Follow the manufacturer's recommendationsfor prolongedstorage,
15. Drain the preservative oil from the
engine crankcase. Reinstall and
tighten the 3/4"-14 square,magnetic drain plug to 45-50 Nom (33-37
Ib-ft)torque.
t 2. Turbocharger_Since turbocharger bearings are pressure lubricated
through the external oil line leading
/tom the oil filter adapter while the
engine is operating,no further attention is required. However, the turbechargerair inletand turbineoutlet
connections should be sealed off
v,.4threeisture-resletanttape.
....
...................
16. Remove and clean the battery and
battery cables with a baking sodawater solution and rinse with fresh
water. Do not allow the soda so]ution to enter the battery. Add distilled water to the electrolyte (if
recessary)and fullycbarge the battery_ Store 'the battery in a coot
(never below 0°C or 32°F) dry place.
Keep the battery fully charged and
check the level and specific gravity
of the electrolyteregularly.
NOTICE:
Failure to properly seal off turbocharger air inlet and exhaust outlet
openings before engine storage may
permit air drafts to circulate through
the turbeeharger and rotate the turbine/compressor shaft without an
adequate flow of lubricatingoil to the
center housing bearings. This can
resultin severebearingdamage,
17. Insert heavy paper strips between
the pulleys and drive belts to prevent
sticking.
18. Seal all engine openings including
the exhaust outlet, with moistureresistant tape. Use cardboard,
ply
wood or metal covers where
practical.
13. Apply a non-friction rust preventive
compound to all exposed engine
parts. If convenient, apply the rust
preventive compound to the engine
flywheel. If not, disengagethe clutch
mechanism to prevent the clutch
disc from sticking to the flywheel,
NOTE:
Do not apply oil, grease or any wax
base compound to the flywheel. The
cast iron will absorb these substances,
which can "sweet" out during operation
and cause the clutch to slip.
19. Clean and dry the exterior painted
surfaces of the engine and spray
with a suitable liquid automobile
body wax, a synthetic resin varnish,
or a rust preventive compound.
20. Protect the engine with a good
weather-resletant tarpaulin and store
it under cover, preferably in a dry
building which can be heated during
the winter months.
14. Drainthe enginecoolingsystem.
7O
Outdoor storage of engine is not
recommended. If units must be kept
out-of-doors, follow the preparation and
storage instructions
already given,
Protect units with quality, weether-realstant tarpaulins (or other suitable covers)
arranged to provide for air circulation,
4. Remove the rust preventive from the
flywheel. Flush any soluble oil rust
inhibitor if used in the cooling systern (see Note, page 70).
NOTICI=-
6. Fillthe crankcase to the proper level
with the required grade of lubricating
oil. Use a pressure lubricator to
insure all bearings and rocker shafts
are lubncated.
5. Remove the paper strips from
between the pulleys and drive belts.
Do not use plastic sheeting for outdoor storage. Plastic is fine for indoor
storage. When used outdoors, however, enough moisture can condense
on the inside of the plastic to rust ferrous metal surfaces and pit aluminum
surfeces. If a unit is stored outside for
7. Fill the fuel tank with the required
fuel.
any extended period of time, severe
corrosion damage can result,
8. Close all drain cocks and fill the
engine cooling system with clean,
soft water and required inhibitors. If
the engine is to be exposed to freezing temperatures,
install genuine
Detroit
Diesel Power
Cool ®
antifreeze or an equivalent ethylene
glycol-base
or propylene
glycolbase antifreeze solution which pro
vides required freeze, boiicver, and
inhibitor protection.
Refer to section
The stored engine should be inspected periodically.
If there are any indications of rust or corrosion, corrective
steps must be taken to prevent damage
to the engine pa,'ts. Perform a complete
inspection at the end of one year and
apply additional treatment as required,
Procedure for Restoring to Service
an Engine that Has Been in
Extended Storage
How to Select Coolant.
9. Install and connect the battery. Make
sure the average specific gravity of
the battery is 1.260 or higher.
Charge the battery if necessary.
1. Remove the covers and tape from
alt of the openings of the engine, fuel
tank and electrical equipment. Do
not overlook the exhaust outlet.
10. Service the air cleaner,/f required.
2. Remove the plugs from the inlet and
outlet fuel lines and reconnect the
lines to their proper positions,
11. Transmission---Follow
the manufacfurer's recommendations
covering the return of the transmission to
service.
3. Wash the exterior of the engine with
fuet oil to remove the rust preventive.
De not wash electrical componewts.
71
12.Power Take-Off (if equipped) -Follow the manufacturer's
recommendations covering the return of
the powertake-off to service,
NOTE:
Before subjecting the engine to a load
or high speed, allow it to reach normal
operating temperature. Then, monitor
the DDEC Diagnostic Data Link for trouble codes.
13.Turbocharger_emove the covors "[TOm
the turbocharger air inlet
and turbine outlet connections.
Reconnect
piping as required.
Prelube the turbocharger.
Refer to
the lubricatingprocedureoutlined in
Preparations for Starting the
Engine the FerstTerne(page 3).
...........
14. After all preparations are completed,
start the engine. The small amount
of rust preventive compound which
remains _nthe _ system will cause
smoky exhaust for a few minutes.
72
SERVICE
PUBUCATIONS
To purchase a copy of any of these
pubfications,
contact an authorized
Detroit Diesel service outlet in the U.S.
or Canada. Check the Yellow Pages
under "Engines, Diesel" or refer tO the
Distributor and Dealer Directory listed
below for the distributoror senile ouflet
nearest you.
The service manual covering Detroit
Diesel Series 60 engines is (isted in
Table 16. ALso listed are reference
works which may be of interest to the
owner/operator,
Description
Form
No.
Series60 EngineServiceManual.............................................................
6SE483
DDEC II Troubleshooting
Guide ................................................................
6SE489
DDECIIIAVSingleECMTroubleshootingGuide .......................................
6SE497
U.S.and CanadaDistributor/DealerDirectory..........................................
6SE280
InternationalDistributor/DealerDirectory..................................................
6SE281
Lube Oil, Fuel, Filter Requirements
...........................................................
7SE270
CoolantRequirementsfor EngineCoolingSystems.................................
7SE298
Technician's
Guide-Used Lubricating
Oil Analysis ................................
7SE398
Table16.Servicepublications
DETROIT DIESEL CUSTOMER ASSISTANCE
U.S. AND CANADA 1-800-445-1980
If you reqd_'eroad servicefor any reason
in the U.S. or Canada,you may call the
1-800-445-1980
customer assistance
phone number. An operator will assist
you in determiningwhat type of service
is required.Not all problemsare engine
mated and not all problems are covered
by engine or vehicle warranties. YOU
MAY BE RESPONSIBLEFOR REPAIR
EXPENSES.
Before calling Customer Assistanee, please do the following:
• Checkcoolantlevel
• Checkfuellevel
• CheckDDECfuses
• Checkfor fuel leaks
• Make sure manseJfuel shutoff valve
(if installed) on secondary fuel fleer
adapter is open.
• Check oil level on the dipstick
• Check diagnosticcodes per page 13
(DDECII)or page 20 (DDECIll/iV).
If you call, have the following
i_on
available:
• Engineserialnumber
• Truck, bus, or equipment make and
model
• Odometermileage
• Truck, bus, or equipmentowner/
companyname
73
CUSTOMER ASSISTANCE
organizations.
The satisfaction
and goodwill
of the
owr_ers of Detroit Diesel engines are of
primary concern to Detroit Diesel
Corporation and its distributor/dealer
uct you have a complete network of over
2,000 Detroit Diesel service outlets in the
U.S. and Canada, plus many outlets
worldwide that are prepared to meet
your parts and sew_e r'4_eds:
As the owner of a Detroit Diesel prod-
Identifythe U.S. regionalares from the map below:
°
EASTERNREGION
WES! k=HNREGION
Long Branch, New Jersey
Downey, California
187Monmouth ParkHighway 10645StudebakerRoad
West Long Branch,NJ07764 Downey,CA 90241
Phone: (732) 222-1888
Phone: {562) 929-7016
Fax:(732)222-3411
Fax:(562)864-0502
SOUTHEASTERNREGION CANADIANREGION
Jacksonville,Florida
London,Ontario
5111 BowdenRoad
Detrc_Dieee}of Car',ariaLld.
Jacksonville,FL 32216
150 DuffefinAve.,Suite701
Phone:(904)448-8833
London,ON N6A5N6
Fax:(904)448-2444
Phone:(519)661-0149
CENTRAL REGION
Fax:(519)66143171
Deb'oit, M'mhitgan
LATINAMB:gCANF,r=c_Y:)N
13400Outer Drive,West
Miami, Ftodda
Detroit, M148239-4001
2277 N.W. 14th Street
Phone:(313)592-5990
Miami,FL33125-0068
Fax: (734)762-1032
Phone:(305)637-1555
SOUft.I',N=_'r=:_IREGION
Fax:(305)637-1580
Dallas,Texas
ASIAN REGION
2711 LBJ Freeway
Suite
1036
DaJlas,
3_X75234
Phone:(972) 247-4313
Fax:(972)247-4316
Singapore
No.
1 BenoiPlace
Singapore629923
Phone:(65)865-1912
Fax:(65)865-1618
74
PACIFIC REGION
Australia
12 DaJgettyRoad
Beaumaris,Victoria3193
Australia
Photo: (61)3-95B9-0454
Fax:(61)3-9589-6858
EUROPE, MIDDLE EAST,
AFRtCA(EMA) REGION
The Netherlands
Ridderpoort9
P.O. Box 4161
2980 GD Ridderkerk
The Netherlands
Phone:(31)1804 63388
Fax:(31)1804-62062
MEXICO
Detroit Diesel Allison de
Mexico
Av. Santa Rosa58
CoLAmpliacionNorte
SanJuan Ixtacala,Tlanepantla
C.P.54160,Edode Mexico
Phone: (525)333-1802
Fax:(525)3.33-1870
• Service by trained personnel,
• Sales teams to help determine
specific n .power requirements,
tact the Detroit Diesel Regional Product
Support or Operations Manager responsible for your local distributor. You will
be assisted by a member of the Manager's staff, depending upon the nature
of your problem.
your
• In many areas,emergencysewice 24
hours a day.
* Complete par_s support including
reliabilt components.
• Product information and literature.
Priorto this contact, havethe following information available:
• Engineserialnumber*
° Name and location of authorized service outlet.
We recognize however, that despite
the best intentions of everyone concemeq, misunderstandingsmay occur.
Normally, any situation that arises in
connection with the sale, operation or
service of your product will be handled
by the authorized service outlet in your
area (inthe U.S. and Canada checkthe
Yellow Pages for the Detroit Diesel ser-
• Type and make of equipment.
* Enginemodeland serialnumber.
• Engine delivery date and accumulated
miles or hours of operation.
° Nature of problem.
° Chronological summary of engine's
history.
vice outlet nearestyou).
To further assure your complete satisfaction, we have developed the following procedure to be followed in the
event you have a problem that has not
been hand_cfsatisfactorily,
*Important: Your engine serialnumber
should be written on the line pro,,4ded, it
will identify your model and all service
parts, plus provide warranty
and
extendedcoverageinformation.
Step One
Step Three
Discuss your problem with a member of
management from the authorized ser-
If you are still not satisfied, present the
entire matter in writing or by phone to:
vice outlet. Frequently, complaints are
the result of a breakdown in communication and can quickly be resolved by a
member of management. If you have
alreadydiscussed the problem with the
Sales or Service Manager, contact the
General Manager. If your complaint originateawith a dealer, explainthe matter
to a management member of the distributorship with whom the dealer has
his serviceagreement,
Vice President, Customer Assurance
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, Michigan 48239-4001
Phone:(313)592-7357
FAX: (313) 592-7888
When contacitngthe regionalor home
office, please keep in mind that urdmataly
your problemwill likelybe resolvedat the
distributorshipor dealership,utilizingtheir
facilities, equipment, and personnel.
Therefore,it is suggestedthat you _low
theabovestepsin seqcence_
ext:x_nsecinga problem.
Step Two
When ft appearsthat your problemcan_
not readilybe resolvedat the distributor
levelwithout additionalassistance,con75
LIMITED WARRANTY ON
NEW DETROIT DIESEL
SERIES
60 ENGINES
USED
Repairs
TO obtain warranty repairs, you must
request the needed repairs within the
WARRANTY PERIOD from an author_ed DE)C service outlet. Only new gen-
IN ON-HIGHWAY
uineparts or remanufaetured pa,rts or
components supplied or approved by
TERMS OF COVERAGE
DDC will be used. DDC may, at its disUses
cretion, replace rather than repair cornThis warranty applies to the first retail
poneets. A reasonable time must be
purchaser and subsequent owners durallowed to perform the warranty repair
ing the WARRANTY PERIOD of new
after taking the angine to the authorized
Detroit Diesel Seties_ 60 _ Engihes
ser_ce o_et: TI"_ owner is responeibte
.....(refe_"to'
_,_ Engir{ei"m'a,_LTra_[Jr_d
by ..... for th'e'[5_Tb_.d_'6T
f_pg.ir dd_:_
Detroit Diesel Corporation and/or supshown in the warranty period chart.
plied by Detroit Diesel Corporation,
Repairs will be performed during normal
Detroit Diesel of Canada
Limited or
business hours.
VEHICLE
APPLICATIONS
Detroit Diesel Overseas Distribution
Corporation (al] which are collectively
referred to as DDC) which are used in
on-highway vehicle applications,
Warranty Period
The WARRANTY PERIOD begins on the
date the engine is delivered to the first
retail purchaser or put in use prior to
Defects
This warranty covers Engine RBDAIRS to
sale at retail, whichever date occurs first,
and
ends at
the time
ter limits
shown
in or
themileage/kilomeWARRANTY
PERIOD chart.
correct any malfunction occurring during
the WARRANTY PERIOD resulting from
defects in mater_ or workmansK_p.
WARRANTY PERIOD
Item
Engine#
Accessories
Warranty Limitabons
(Whichever Occurs First)
MONTHS
MILES/
KILOMETERS
Repair Charges to be
Paid by Owner
PARTS
LABOR
0-24
0-24
Unlimited
No Charge
No Charge
0-50,000 miles
No Charge
No Charge
0-80,000 km
No Charge
No Charge
Upon expiration of the 24month warranty covera_re, but within 500, O00mi/
800,000 km of use, the warranty continues to apply as follows:
100% of
Major
25-60
0-500,000
No Charge
sewice ouUet's
Componentst
0-800,000 miles
km
normal charge
# IndudesJacobsVehicleSystemsBrakingDevicesand50 DNAitem_ors,if Instal_d.
1-CylinderBlock/Head,Crankshaft,Camshaft,MainBeatingBo_ts,FlywheelHousing,Connecting
RodAssemblies,OilCoolerHousing,WaterPump Housing,andAirIn_ Housaqg,
andTF550Air
Compressorsif so equipped.
76
THIS WARRANTY DOES NOT
COVER:
LikeReplacementEngine
Engine(s) supplied by DDC as a replacement for an engine still under warranty
will assume the identity of the engine
being replaced and be entitled to the
remaining warranty coverage.
Repairs Due to Accidents, Misuse,
Storage Damage, Negligence or
Certain Modifications
Repairs due to an accident, misuse,
misapplication,storage damage, negligence or modification exceeding DDC
specifications are net covered by this
warranty.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusabledue to neededwarrantyrepairs
iscovered by this warranty.
Braking Devices
DDC is not responsiblefor the repair of
non-Jacobs Vehicle Systems mechanieal braking devices installed on the
engine. Such devicesare warranted by
the brake manufacturer.
EngineRemoval and Reinstallation
Labor costs for Engine removal and
reinstallation,whennecessaryto make a
warranty repair, are covered by this warrarity.
Fuel Injectors After 100,000
Miles/160,000 Kilometers
The repair or replacement of fuel injectors after 100,000 miles/160,OOOkilometers of operation is not covered by
this warranty.
77
Maintenance
Other Limita_ons
DDC is not responsible for the cost of
The performance of REPAIRS is the
maintenance or repairs due to lack of
exclusive Owner's remedy under this
performance of required maintenance
warranty. Detroit Diesel Corporation
cervices as recommended by DDC, or
does not authorize any person to
the failureto use fuel, oil. lubricantsand
assumeor create for it any other obligacoolant meeting DDC-reeommended
lion or liability in connection with the
specifications.
Performance
of the
engine or the accessories.
required maintenance and use of proper fuel, oil, lubricants and coolant are
THiS WARRANTY AND THE EMISthe responsibilityof the owner. Refer to
SIONS CONTROL WARRANTY ARE
the "Lubrication
and Preventive
THE ONLY WARRANTES APPUCABLE
Maintenance Intervals" section oflhis
TO THE ENGINE AS 1.1SED+INON+
Operatdr"s Gu]de'f_r deters.
................. HIGHWAY VENICt-E _,P_PEIOATIONS.
DETROIT DIESEL CORPORATION
Incidentalor Consequential
MAKES NO OTHER WARRANTIES
Damages
EXPRESS OR IMPLIED, INCLUDING
DetroitDieselCorporation_snot reaponANY iMPLIED WARRANTY OF MERsiblefor incidentalor consequentialcosts
CHANTABIUTY OR FITNESS FOR A
or expenseswhich the owner may incur
PARTICULAR PURPOSE. DETROIT
as a resultof a malfunctionor failurecovDIESEL CORPORATION SHALL NOT
ered by this warranty, such as commeniBE UABLE FOR ANY INCIDENTAL OR
cation expenses, meals, lodging,
CONSEQUENTIAL DAMAGES AS
overtime, towing, loss of use of tile
DESCRIBED ABOVE.
engine or vehicle ("downtime"), loss of
time, inconveniences, cargo toss or darnSome states do not allow the [_itation of
age,and other siml]ercosts and expenshow long this warranty may last or the
es.
limitationor exclusionof incidentalor
consequential
damages, so the above
may not apply to you. This warranty gives
you specific legal rights, and you may
also have other rights which may vary
from state to state.
78
LIMITED WARRANTY ON
Defects
NEW DETROIT DIESEL
This warranty covers Engine REPAIRS
tO correct any malfunction occurring
during the WARRANTY PERIOD result-
SERIES
60 ENGINES
ENGINE
ACCESSORIES
AND
ing from defects in material or workmanship.
USED IN CONSTRUC-
Repairs
To obtain warranty repairs, you must
request the needed repairs within the
WARRANTY PERIOD from an authorized DDC service outlet. Onty new genuine parts or remanufactured parts or
components supplied or approved by
DDC will be used. DDC may, at its discretion, replace rather than repair eomponents. A reasonable time must be
aJlowed to perform the warranty repair
alter taking the engine to the authorized
service outlet. Repairs will be performed
during normalbusinesehours.
TION_NDUSTRIAL
APPLICATIONS
TERMS OF COVERAGE:
Uses
This warranty applies to the first retail parchaser and subsequent owners during
the WARRANTY PERIOD of new DetreE
Diesel Series 60 _ Engines (referred to as
Engine) manufactured by Detroit Diesel
Corporation and/or supplied by Detroit
Diesel Corporation,
Detroit Diesel of
Canada Limited or Detroit Diesel
Overseas Distribution
Corporation
(all
which are collectivety referred to as DDC)
which are used in constructionf_qdustrial
applications,
ITEM
Engine
Accessories
Block.Crankshaft
and
Connecting Rods
The owner is responsible for the percentage of repair costs shown in the
WARRANTY PERIOD CHART.
WARRANTY
PERIOD
Warranty limitations
Adjustment Charge to
(Whichever Occurs First)
be Paid by file Owner
MONTHS ENGINEHOURS
pARTS
LABOR
0-12
NOUmit
NoCharge
NoCharge
0-12
0-2,000
NoCharge
NoCharge
Up__e,'_r_Uz2n
ofgqetwelve(12)_
w_'rsz_co_,
b_ w,:fl_
12,000hoursof use,UTe
wanaz_continues
toapplyasfogows:
13-36
0-12,000
Warranty Period Chart
79
No Charge
No Charge
Warranty Period
The WARRANTYPERIODbeginson the
date the Er_
is deliveredto the first
retailpurchaseror put in use priorto sale
at retail,whicheverdateoccurs _st, and
ends at the time or hour limitsshown in
the WARRANTYPERIODchart on the
precedingpage.
THIS WARRANTYDOES NOT
COVER:
Repairs Due to Accidents, Misuse,
Storage Damage, Negligence or
Certain Modifications
Repairs due to an accident, misuse,
misapplication, storage damage, negligence or modification exceeding DDC
specifications are not covered by this
warranty.
....
_Remevat
andReiestallationA_b.er_'_
al_l'S1_fid:.......
by Pump Applications
Labor and material costs for engine
removal end ralnsta[lation,when necessary to make a warranty repair, are not
covered by this warranty when the
engine is in an agfioultureJmachineryor
stand-bypump application.
Service Supplies
The cost of service supplies such as
cooant oil and filters which are not
r_usab e dueto _vartat3i:edrepairs is
coveredby this war4ranty
_......................
Engine Removal and ReinstatiatJonCons'aruction/Indt_ial Applica_ons
Reasonabte labor costs for engine
removaland reinstallation,when necessaryto make a warrantyrepair,are covered by this warranty during the first
twelve(12)monthsof service.
Non-DDC Supplied/Manufactured
Components
DDC is not responsible for repair of
components and/or assemblies which
are manufacturedor suppli_d by another manufacturer,
such as non-DDC
power take-offs and intake and exhaust
systems.Such itemsare coveredby the
equipmentmanufacturer.
Mechanic's Travel Expenses
DDC will pay reasonable travel expens_
es for the repairingmechanicto travel to
and from tb_ repairsite.
like Replacement Engine
Engine(s)suppliedby DDCas a replacement for an Enginestill under warranty
will assume the identity of the Engine
being replaced and be entitled to the
remainingwarrantycoverage.
80
Maintenance
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
Other Limitations
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize any
person to assume or create for it any
other obligation or liability in connection
with the Engineor the Accessories.
the failure to use fuel, oil, lubricants and
coolant meeting DDC-recommended
specifications. Performance of the
requiredmaintenanceand useof proper
fuel, oil, lubncantsand coolant are the
responsibility of the owner. Refer to the
"Lubrication and Preventive Maintenance Intervals" Section of this
Operator'sGuidefor details.
THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE
THE ONLY WARRAN_ES APPUCABLE
TO THE ENGINEAND ACCESSORIES
AS USED IN CONSTRUCTION_NDUSTRIAL, AGRICULTURALMACHINERY
AND STAND-BYPUMPAPPUCATIONS.
DETROIT DIESEL CORPORATION
MAKES NO OTHER WARRANTIES
Ir_idental orO_seque_al
Damages
DDC;is not responsible for incidentalor
consequential costs or expenses which
the owner may incur as a result ot a realfunction or failure covered by this warranty, such as communication expenses,
meals,lodging,overtime,towing,and any
associatedloss of use of the Engine or
equipment ("downtime"), loss of time,
inconvenience, cargo loss or damage,
and other similar costs and expenses.
EXPRESS OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. DETROIT
DIESEL CORPORATION SHALL NOT
BE UABLE FOR ANY INCIDENTALOR
CONSEQUENTIAL
DAMAGES AS
DESCRIBEDABOVE.
Some states do not allow the limitation of
how long this warranty may last or the
limitation or exclusion of incidental or
consequential damages, so the above
may not apply to you. This warranty gives
you specific legal rights, and you may
also have other rights which may vary
from state to state.
81
LIMITED WARRANTY ON
Repairs
NEW DETROIT DIESEL
SERIES 60 ENGINES
To obtain warranty repairs, you must
request the needed repairs within the
WARRANTY PERIOD from an autho-
USED
IN
rized DDC service outlet. Only new
genuine parts or remanufaetured parts
or components supplied or approved
by DDC will be used. DD C may, at its
discretion, replace rather than repair
components. A reasonable time must
be allowed to perform the warranty
repair after taking the engine to the
authortzed se_ice outlet. Repairs will
be
hours.performed during _ormat busieess
TRUCK OR CRASH
RESCUE
VEHICLE
APPLI-
CAllONS
TERMS OF COVERAGE
Uses .................
ThTs"_2_f_6_ Epplles t6 t6_'fir'sf r_{eil
purchaser and subsequent
owners
during the WARRANTY PERIOD of
new Detroit Diesel Series 6CP Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation and/or
supplied by Detroit Diesel Corporation,
Detroit Diesel of Canada
Limited or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
fire truck or crash rescue vehicle
applications.
Warranty Period
The WARRANTY PERIOD begins
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail, whichever date occurs
first, and ends at the time or
mileage/kilometer
limits shown in the
WARRANTY PERIOD chart.
Like Replacement
Engine
Engine(s) supplied by DDC as a
replacement
for an engine still under
warranty will assume the identity of the
engine being replaced and be entitled
to the remaining warranty coverage.
This warranty covers Engine REPAIRS to
correct any malfunction occurring during
the WARRANTY PERIOD resulting from
defects in material or workmanship,
WARRANTY PERIOD
Item
Warranty
(Whichever
MONTHS
Engine
0-60
Accessories
0-24
on
Limitations
Occurs First)
AMES/
KILOMETERS
0-50,000 miles
0-80,000 km
0-50,000 miles
0-80,000 km
82
Repair Charges to be
Paid by Owner
PARTS
LABOR
No Charge
No Charge
No Charge
No Charge
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to needed warranty
repairs is covered by this warranty,
Maintenance
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oii, lubricants
and coolant meeting DDC-recommended specifications. Performance
of the required maintenance and use
of proper fuel, oil, lubricants and
coolant are the responsibility
of the
owner. Refer to the "Lubrication and
PreventiveMaintenance intervals" section of this Operator'sGuide for details.
Engine Removal and
Reinstallation
Reasonable labor costs for Engine
removal and reinstallation, when necessary to make a warranty repair, are
covered by this warranty,
THIS WARRANTY DOES NOT
COVER:
Incidental or Consequential
Damages
Detroit Diesel Corporation
is not
responsible for incidental or consequential costs or expenses which the
owner may incur as a result of a realfunction or failure covered by this
warranty,
such as communication
expenses, meals, lodging, overtime,
towing, loss of use of the engine or
vehicle ("downtime"),
loss of time,
inconveniences,cargo loss or damage,
and other similar costs and expenses.
Repairs Due to Accidents,
Misuse, Storage Damage,
Negligence or Certain
Modifications
Repairs due to an accident, misuse,
misapplication, storage damage, negligence or modification
exceeding
DDC specifications are not covered by
this warranty,
83
Other Lim;:--::ons
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. Detroit Diesel Corporation
does net authorize any person to
assume or create for it any other obligatlon or liability in connection with the
engine or the accessories.
THIS WARRANTY AND THE EMIS-
LIMITED
WARRANTY
ON NEW DETROIT
DIESEL SERIES 60
ENGINES
USED
IN
AGRICULTURAL
MACHINERY
TERMS OF COVERAGE
SIONS CONTROL WARRANTY ARE
Uses
THE ONLy WARRANTIES APPLICA__i_h_s_arraoty
applies t0__be_first_
BL E TO THE_._TN.E_,AS ILISED IN..............
_etaiJ..purchase r
subsequent
FIRE TRUCK OR CRASH RESCUE
owners during the WARRANTY
VEHICLE APPLICATIONS. DETROIT
PERIODof new Detroit Diesel Series
DIESEL CORPORATION MAKES NO
60® Engines (referred to as Engine)
OTHER WARRANTIES EXPRESS OR
manufactured
by Detroit Diesel
IMPLIED, INCLUDING ANY IMPLIED
Corporation and/or supplied by
WARRANTY OF MERCHANTABILITY
Detroit Diesel Corporation,
Detroit
OR FITNESS FOR A PARTICULAR
Diesel of Canada Limited or Detroit
PURPOSE.DETROITDIESELCORPODiesel
Overseas
Distribution
Corporation (all which are collectiveRATION SHALL NOT BE LIABLE FOR
ly referred to as DDC) which are
ANY INCIDENTAL OR CONSEQUENused in agricultural machinery.
TIAL DAMAGES AS DESCRIBED
ABOVE.
This warranty covers Engine REPAIRS
Some states do not allow the limitation
to correct any malfunction occurring
of how long this warranty may lest for
during the WARRANTYPERIODresulting from defects in material or workthe limitation or exclusion of incidental
manship.
or consequential damages, so the
above may not apply to you. This warRepairs
ranty gives you specific legal rights,
To obtain warranty repairs, you must
and you may also have other rights
request the needed repairs within the
which may vary from state to state.
WARRANTYPERIOD from an authorized DDC service outlet. OnJynew
genuine parts or remanufactured
parts or components supplied or
approved by DDC will be used. DDC
may, at its discretion, replace rather
than repair components. A reasonable time must be allowed to perform
the warranty repair after taking the
engine to the authorized service outlet. Repairs will be performed during
normal business hours.
84
Warranty Period
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sate at retail, whichever date occurs
first, and ends at the time or limits
shown in the WARRANTY PERIOD
charL
Engine Removal and
Reinst_laUon
Labor costs for Engine removal and
reinstallation,when necessary to make
a warranty repair, are not covered by
this warranty.
Non-DDC Supplied/Manufactured
Components
DDC is not responsible for repair of
components and/or assemblies which
are manufactured or supplied by
another manufacturer, such as intake
and exhaust systems. Such items may
be covered by warranties issued by
the manufacturer or supplier.
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an engine still under
warrantywill assume the identity of the
engine being replaced and be entitled
to the remaining warranty coverage,
8ervise Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to needed warranty
repairs is covered by this warranty,
THIS WARRANTY
COVER=
DOES
Maint_m_mc_e
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants
and coolant meeting DDC-recommended specifications.
Performance
of the required maintenance and use
of proper fuel, oil, lubricants and
coolant are the responsibility of the
owner. Refer to the "Lubrication and
Preventive Maintenance Intervals" section of this Operator's Guide for details.
NOT
Repairs Due to Accidents,
Misuse, Storage Damage,
Negligence or Certain
ModificaUons
Repairs due to an accident, misuse,
misapplication,
storage damage, neg]igence or modification
exceeding
DDC specifications are not covered by
this warranty.
WARRANTY
Item
Engine
Accessories
PERIOD
Warranty LimitaUons
(Whichever Occurs First)
ENGINE
Houas
Up to 36
Up to 2,500
Up to 12
Up to 2,000
85
Repair Charges to be
Paid by Owner
PARTS
LABOR
No Charge
No Charge
No Charge
No Charge
IncidentalorConsequential
Damages
LIMITED WARRANTY ON
NEW' DETROIT DIESEL
This warranty does not cover any ec_
comic loss, including without limitation,
communicationexpenses, meals, Iod_
SERIES
ing, toss of use of the Engine or equipment, loss of time, inconvenience,
cargo damage, overtime,towing or any
other cost or expense resulting from a
defect covered by this warrant.
....
60 ENGINES
USED IN
PRIME POWER
GENERATOR
SETS
TERMS OF COVERAGE
Olher LimilaUons- ................
THtS WARRA1qq-'Y"IS'"TRE ONL'f
Uses_ ......._ ......................
.... This.wa_-ra_ a#plies,to the first retail....
purchaser and subsequent owners
WARRANTY APPLICABLE TO THE
during the WARRANTY PERIOD of
ENGINE AS USED IN AGRICULTURnew Detroit Diesel Series 60_ Engines
AL MACHINERY APPLICATIONS.
(referred to as Engine) manufactured
DETROIT DIESEL CORPORATION
by Detroit Diesel Corporation and/or
MAKES NO OTHER WARRANTIES
supplied by Detroit Diesel Corporation,
EXPRESSOR IMPLIED, INCLUDING
Detroit Diesel of Canada Limited or
ANY IMPLIED WARRANTY OF MERDetroit Diesel Overseas Distribution
CHAN-IABILITY OR FITNESS FOR A
Corporation (all which are collectively
PARTICULAR PURPOSE. DETROIT
referred to as DDC) which are used in
DIESEL CORPORATIONSHALL NOT
prime power generators delivered in
BE LIABLE FOR ANY INCIDENTAL
the U.S. or Canada.
OR CONSEQUENTIAL DAMAGES AS
DESCRIBEDABOVE.
ThiswarrantycoversEngineREPAIRSto
correct any malfunction cocurdng during
Some states do not allow the limitation
_e WARRANTY"
PERIODresufiing from
of how long this warranty may last for
defects in materiel or workmanship.
the limitationor exclu,d_onof incidental
or consequential damages, so the
Repairs
To obtain warranty repairs, you must
above may not apply to you. This warrequest the needed repairs within the
rarity gives you specific _egal rights,
WARRANTY PERIOD from an authoand you may also have other rights
rized DD_ _ervice outlet. Only new
which may vary from Stateto state,
genuine parts or remanufactured parts
or components suppJied or approved
by DDC will be used. DDC may, at its
discretion,
replace rather than repair
components. A reasonable time must
be allowed to perform the warranty
repair after taking the engine to the
authorized
service outlet. Repairs will
be performed during normal business
hours.
86
Warranty Period
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail,whichever date occurs
first, and ends at the time limits shown
in the WARRANTYPERIODchart.
THIS WAFIRANTY DOES NOT
COVER:
Repairs Due to Accidents,
Misuse, Storage Damage,
Negligence or Certain
Modifications
Repairs due to an accident, misuse,
misapplication, storage damage, negligence or modification exceeding
DDC specifications are not covered by
this warranty.
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an engine still under
warranty will assume the identity of
the engine being replaced and be
entitled to the remaining warranty
coverage.
Engine Removal and
Reinstallation
Reasonable labor casts for Engine
removal and reinstallation, when necessary to make a warranty repair, are
covered by this warranty.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to needed warranty
repairs is covered by this warranty.
Non-DDC SeppUed/Manufactured
Components
DDC is not responsible for repair of
components and/or assemblies such
as intake and exhaust systems and
fuel storage tanks which are manufactured or suppfled by another manufacturer. Such items may be covered by
the equipment manufacturer.
Mechanic's Travel Expenses
DDC will pay reasonable travel
expenses for the repairing mechanic
to travelto and from the repair site.
WARRANTY
item
PERIOD
Warranty Limitations
(Whichever Occurs First)
Repair Charges to Be
Paid by Owner
MONTHS
PA]_rs
ENGINE
HOURS
Engine
0-12
Unlimited
No Charge
No Charge
Uponexpiration of the 12 month warranty coverage, but within 12,000 hours of
Joe, the warrant _continues to apply as follows:
Block,
100% of
crankshaft,
13-36
0-12,000
No Charge
service outlet's
andconnormal
charge
necting rods
(assemblies
87
lUlaint_nam_
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants,
cooling air and ventilation meeting
DDC-recommended specifications,
Performance of the required maintenance and use of proper fuel, oil, {ubricants, cooling air and ventilation are
the responsibility of the owner. Refer to
the _Lubrication 'and--Preventive
Maintenance tiit"_rV_1_;"_tTon'_f th)'_
Operator'sGuide for details.
Other l.im;_.-: -',_
THIS WARRANTYIS THE ONLY WARPANTYAPPLICABLETO THE ENGINE
AS USED IN PRIME POWERGENERATORS.DETROITDIESELCORPORATION MAKES NO OTHER WARRANTJES EXPRESS OR IMPLIED,
iNCLUDING ANY IMPLIEDWARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. Dt=IHOIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR
ANY 1NC1DElkq'A1_
OR-CONS_EQIJE_::.
TI'AL" [3;_._GES AS' [3EsCRiE3ED
ABOVE.
Incidental or _,,eCllU_t_al
Damages
This warranty does not cover any economic loss, including without limitation
communicationexpenses, meals, Iodging, loss of use of the Engine, less of
time, inconvenience, overtime, transportation of the Engine or any other
cost or expense resulting from a defect
covered by this warranty.
Some states do not allow the limitation
of how brig this warranty may last for
the limitation or exclusion of incidental
or consequential damages, so the
above may not apply to you. This warrarity gives you specific legal rights,
and you may also have other rights
which mayvary from s_.teto state.
88
LIMITED WARRANTY ON
warranty
Pe_od
NEW
DETROIT
_r_
_
USED IN STAND-BY
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail, whichever date occurs
POWER GENERATOR
first, and ends at the time limits shown
DIE_F._
P_G|NF_
intheWARRANTY
PERIOD
chart.
Uke Replacement
Engine
Engine(s) supplied by DDC as a
TERMS OF COVERAGE
Uses
This warranty applies to the first retail
purchaser and subsequentowners during the WARRANTY PERIOD of new
Detroit Diesel Series 60 ® Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation and/or
supplied by DetToitDiesel Corporation,
Detroit Diesel of Canada Limited or
Detroit Diesel Overseas
Distribution
Corporation
(all which are collectively
referred to as DDC) which are used in
stand-by
generators delivered in the
U.S. or Canada.
replacement for an engine still under
warranty will assume the identity of the
engine being replaced and be entitled
to the remaining warranty coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to needed warranty
repairs is covered by this warranty.
Mechanic's Travel Expenses
DDC wilt pay reasonable travel
expenses for the repairing mechanic
to travelto andfromtherepairsite.
This warranty covers Engine REPAIRS to
correct any maJfunctianoccurringduring
the WARRANTY PERIOD resulting from
defects in matedsJ or workmanship.
THIS WARRANTY DOES NOT
_11_
Repairs
To obtain warranty repairs, you must
request the needed repairs within the
WARRANTY PERIOD from an authorized DDC service outlet. Only new
genuine parts or remanufactured parts
or components supplied or approved
by DDC will be used. DDC may, at its
discretion,
replace rather than repair
components. A reasonable time must
be allowed to perform the warranty
repair after taking the engine to the
authorized service outlet. Repairs will
be performed during normal business
hours.
Repairs Due to Accidents,
Misuse, Storage Damage,
Negligence or Certain
Meditr_._li_
Repairs due to an accident, misuse,
misapplication, storage damage, negligence or modification
exceeding
DDC specifications are not covered by
this warranty.
89
Engine Removal and
Reinstolla'Uorl
Reasonable labor costs for Engine
removal and reinstallation, when neeessary to make a warranty repair, are
covered by this warranty,
Non-ODC Supplied/Manuf-acturscl
_lx,_dls
DDC is not responsible
for repair of
components and/or assemblies such
as intake and exhaust systems and
AJeLstorage-tanks which ar4_manufac-t_e_ _r._ttppt_ed. by another manuf ac- ....
turer. Such items may be covered by
warranties issued by the manufacturer
or supplier.
Maintenance
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants
and coolant meeting DDC-recommended specifications.
Performance
of the required maintenance
and use
of proper
fuel, oil, lubricants
and
coolant are the responsibility of the
owner. Refer to the "Lubrication and
Preventive Maintenance
Intervals" section of this Operator's Guide for details,
Item
Engine
Other Um;;.,:-'ons
THIS WARRANTY-IS THE ONLY WARRA'NTY APPL1CA'BEE q-O THE ENG1NE ....
AS USED IN STAND-BY GENERATons. DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR
FITNESS FOR A PARTICULAR PunPOSE. DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED
ABOVE.
Some states do not allow the limitation
of how tong this warranty may last for
the limitation or exclusion of incidental
or consequential
damages,
so the
above may not apply to you. This warranty gives you specific
_egal rights,
and you may also have other rights
which may vary from state to state.
WARRANTY
Warranty
(Whichever
MONTHS
Up to 24
IncideNtal or ColIL_,eql_11_ial
_m;Kjes
This warranty does not cover any economic toss, including without limitation
communication expenses, meals, Iodging, loss of use of the Engine, loss of
time, inconvenience,
overtime,
transportation of the Engine or any other
cost or expense resulting from e defect
covered by this warranty.
PERIOD
Limitations
Occurs First)
ENGINEHOURS
0-800
9O
Repair Charges to Be
Paid by Owner
pARTS
LABOR
No Charge
No Charge
SPECIFICATIONS
FILTERS
Table 17. FUEL FILTER REQUIREMENTS-Series 60 Regular Service
Filter Type
De'm0lt Diesel Part No.
Primary
Spi_n
23518481
Primary Water/Separator, Spin--Ont
23512317t
Fuel Pro 380/380E Pdmary Element
23521528
SecondarySpin--On
23518482
FUEL RLTER -- Optional Service
Fuel Pro 380/382 Secondary
23511528
LUBRICATING OIL FILTER ELEMENT REQUIREMENT
Filter Type
Fuji Flow
Detroit Diesel Part No.
23518480
FullFlow(HighCapacity)
FullFlow#
23524251
23523701#
t Optional. May be used in place of, but not together with, pdmary rifler.
# For use with synthetic lubncating oil onEy.
Table 18. OIL PAN CAPACITY
All Series 60 on-highway truck oil pans (front sump and rear sump)
require the same amount of engine oil:
26 quarts to the LOW mark ............................................... W'ithout oil filters
32 quarts to the FULL mark ............................................... Wr_houtoil filters
TOTAL OIL CAPACITY OF THE ENGINE
40 quarts
to the FULL
mark
...............................................
With oil filters installed
and filters and oil
galleries
charged.
POWER COOL ENGINE PRODUCTS
Table 19. Power Cool Fully Formulated lEG Coolant
Coolant Type
Part Number
Concentrated
23512138
23512139
One GallonJug -- 6 Per Case
55 Gallon Drum
23512140
23518918
Bulk Delivery-- 1,000 Gallon Min.
55 Gallon Drum
23513503
Bulk Delivery -- 1,000 Gallon Min.
Pr_Blended 50:50
91
Description
POWER COOL ENGINEPRODUCTS (Cont.)
Table 20. Power Cool 2000 SupplementalCoolant Additive
Coolant Type
ForPowerCool
lEG Coolant
Port Number
23507858
De.scdption
PintBottle -- 12 Per Case
23507859
23507860
Half Gallon Jug -- 6 Per Case
5 Gallon Pall
23507861
55 GallonDrum
................ Table 21; Power Coo/.3e0OSupplelneldalC_olant.Additive...............
CoolantType
ForPowerCool
lEG Coolant
Port Number
23507854
Description
Pint Bottle- 12 Per Case
23507855
23507856
Half Gallon Jug -- 6 Per Case
5 Gallon Pall
23507857
55 GallonDrum
Table 22. Power Coo/3000 SupplementalAdditiveCoolant Filters
CoolantType
Part Number
Descripfdon
ForPowerCool
lEG Coolant
23507545
4 Ounce (1 PintEquivalent)
23508425
23508426
8 Ounce(2 PintEquivalent)
12 Ounce (3 Pint Equivalent)
23507189
16 Ounce (4 Pint Equivalent)
23508427
32 Ounce (8 Pint Equivalent)
23508428
53 Ounce(13 PintEquivalent)
Table 23. Power Coo/Supplemental Additive Need Release Coolant Filters
Coolant Type
Part Number
Description
ForPowerCool
lEGCoolant
23516488
For 0-8 GallonSystems
23516489
For 8 20 Gallon Systems
92
POWER COOL ENGINE PRODUCTS
Table 24 PowerCool
Plus Extended Life NOAT Coolant
Coolant Type
Part Number
Concentrated
23519394
55 GallonDrum
23519395
Bulk Delivery -- 1,000 Gallon Min.
23519396
23519398
One Gallon Jug -- 6 Per Case
55 Gallon Drum
23519399
Bulk Delivery -- 1,000 Gallon Min.
Pre-Blended 50:50
Description
Table 25. Power Coo/Plus Extender for Use with
Power Cool Plus NOAT Coolant
Coolant Type
For Power Coo/Plus
Part Number
I
23519400
I
Description
One Quart Bottle -- 6 Per Case
Table 26. Power Coo/Plus 6000 OAT Inhibitor for Water-Only Systems
Coolant Type
Part Number
Water Only
23522127
One GallonJug -- 6 PerCase
23522128
5 Gallon Pail
93
Description
POWER COOL ENGINE PRODUCTS
Table 27. Power Coo/Cooling System Cleaners
Cleaner Type
Part Number
Description
On_UneCleaner
TwinPack
23507862
23507863
One-HalfGallonJug -- 6 Per Case
5 Gallon Pall
23507864
55 Gallon Drum
23507867
TwinPack-- 2 PerCase
Table 28. Power Trac Coolant Testing & AnalysisProducts
....... Applica_on..................
pa_Number ...............
Desc_o_ion...................................
IndicatesNitrite,Molybdate& GlycolLevels
23519401
3-Way CoolantTest Stnps
(SingleFoilPacks)
Indicates Nib'ite, Molybdate&GlycolLevels
23519402
3-Way Coolant Test Strips
(Bottleof 50)
Indicates Nitrite,
Molybdate
& Glycol
Levels
23522774
3-Way Coolant Test Strips
(Bottleof 10)
Complete IG PG
CoolantAnalysis
23516921
Coolant AnalysisBottle
(Cartonof 6)
Complete NOAT
CoolantAnalysis
23523398
Coolant AnalysisBottle
(Cartonof 6)
94
NOTES
95
NOTES
97
13400 Outer Onve, West / Detroit, Michigan
48239
4001
Telephone:
313-592
5000
www detroitdiese[
corn
Detl'Ol[_e_c_ Det_t [_e_e_
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DDEC III/IV System
Flash Codes
TO READ CODES: Use the dragnosticdata reader or depress and hold the dragnostic rewest switch wrth the ~gnitro”on. engrneat Idle or not runnrng Press and tdu
the switch Active codes wrll be flashed on the sto,, engrne Ilght, followed by the
lnactlve
operator
Flash
Codes
11
12
13
14
15
16
17
16
21
22
23
24
25
26
27
28
31
32
33
;z
36
37
38
41
42
43
44
45
46
47
48
52
53
54
55
56
57
58
::
63
64
65
66
67
68
71
72
::
75
76
77
a1
a2
a3
a4
a5
a6
07
aa
Codes being flashed on the check eng,ne
releases the diagnostic
request swtch
DDEC System
light
The cycle
WIII repeat
unf~l the
Description
VSG sensor Input voltage low
VSG sensor Input voltage hfgh
Coolant level sensor Input voltage low
011,coolant, or Intercooler, temp. sensor rnpur voltage hrgh
911,coolant, or Intercooler, temp sensor Input voltage low
Coolant level sensor Input voltage hrgh
Bypass or throttle, valve positron sensor Input voltage hrgn
Bypass or throttle, valve posrtron sensor Input voltage low
TPS Input voltage hrgh
TPS Input voltage low
Fuel temp sensor Input voltage high
Fuel temp. sensor Input voltage low
No active codes
Aux. engine shutdown #l, or #2, input actrve
Arr Inlet or Intake air, temp. sensor Input voltage htgh
Air Inlet or intake air, temp. sensor input voltage low
Aux. high side output open crrcuit or short to ground
CEL or SEL short to battery (+) or open crrcurt
Turbo boost sensor Input voltage high
Turbo boost sensor Input voltage low
Oil pressure sensor Input voltage high
Oil pressure sensor Input voltage low
Fuel pressure sensor input voltage hrgh
Fuel pressure sensor Input voltage low
Too many SRS (missing TRS)
Too few SRS (mrssrng SRS)
Coolant level low
011,coolant, Intercooler or Intake arr, temp. high
011 pressure low
ECM battery voltage low
Fuel, arr inlet, or turbo boost, pressure hrgh
Fuel or air Inlet pressure low
ECM A/D conversion fault
ECM non volatrle memory fault
Vehrcle speed sensor fault
J1939 data lrnk fault
J1587 data lrnk fault
J1922 data lrnk fault
Torque overload
Injector response trme long
Aux output short to battery (+) or open crrcurt. or mech. fault
PWM drive short to battery (+) or open crrcurt
Turbo speed sensor Input fault
Throttle valve posrtron Input fault
Engrne knock sensor Input fault
Coolant or arr inlet, pressure sensor Input voltage fault
TPS Idle valrdatron swatch open circurt or short to ground
Injector response trme short
Vehrcle overspeed
Gas valve posrtron Input fault or ESS fault
Optrmrzed Idle’* safety loop short to ground
ECM Battery voltage hrgh
Engrne overspeed with engrne brake
Fuel temperature hrgh
Oil level, crankcase prs, dual fuel 801, or exh. temp. volt. hrgt
011level, crankcase prs, dual fuel 801, or exh. temp. volt low
011 level, crankcase prs. exhaust temp., or external pump prs.
hrgh
Oil level or crankcase pressure, low
Engrne overspeed
External pump or barometer, pressure sensor Input voltage
high
External pump or barometer, pressure sensor Input voltage
low
Coolant pressure low
SAE Faults
SAE
Faults
Flash
Code
po51 0
po51 1
po51 3
PO51 4
po51 7
po52 0
~052 3
po52 4
po70 4
~072 3
~072 4
po73 0
po73 3
po73 4
poa4 0
poa4 11
poa4 12
PO91 3
PO91 4
po92 0
po94 0
po94 1
po94 3
po94 4
3098 0
3098 1
3098 3
3098 4
SlOO 1
,100 3
3100 4
3101 0
3101 1
,101 3
,101 4
,102 0
,102 3
,102 4
,103 a
,105 0
I105 3
)1054
,106 0
,106 1
,106 3
,106 4
11083
,108 4
,109 1
,109 3
,109 4
,110 0
,110 3
Ill04
1111 1
1111 3
1111 4
I121 0
65
65
17
ia
65
44
14
15
74
17
18
a3
86
a7
72
72
1168 0
1168 1
1172 3
,172 4
‘173 0
173 3
1734
174 0
174 3
174 4
2”;’
22
58
47
48
37
38
a3
a4
a1
a2
45
35
36
a3
a4
81
a2
47
33
34
64
44
27
28
47
48
67
67
86
a7
aa
67
67
44
14
15
43
16
13
76
75
46
27
28
a3
a3
a3
77
SAE Faults
DDEC System
Description
SAE
Faults
Flash
Code
Throttle valve posrtron above normal range
Throttle valve posrtton below normal range
Throttle valve input voltage high
Throttle valve Input voltage low
Throttle valve not respondrng
Intercooler temp hrgh
Intercooler sensor input voltage high
Intercooler sensor Input voltage IOW
Optrmrzed Idle safety loop short to ground
Bypass posltlon sensor Input voltage hrgh
Bypass posrtion sensor Input voltage low
External pump pressure hrgh
Pump pressure sensor input voltage high
Pump pressure sensor Input voltage low
Vehrcle overspeed (fueled)
Vehicle overspeed (absolute)
Vehicle speed sensor farlure
Throttle posrtion sensor Input voltage high
Throttle posrtron sensor Input voltage low
Torque overload
Fuel pressure high
Fuel pressure low
Fuel pressure sensor Input voltage high
Fuel pressure sensor input voltage low
011 level hrgh
011 level low
011level sensor Input voltage high
011level sensor Input voltage low
011pressure low
011pressure sensor Input voltage hrgh
Or1pressure sensor Input voltage low
Crankcase pressure hrgh
Crankcase pressure low
Crankcase pressure sensor input voltage htgh
Crankcase pressure sensor Input voltage low
Turbo boost pressure hrgh
Turbo boost oressure sensor Input voltage high
Turbo boost pressure sensor Input voltage low
Turbo speed sensor input farlure
Intake air temp. hrgh
Intake arr temp. sensor Input voltage nrgh
Intake air temp. sensor Input voltage low
Air inlet pressure high
Arr inlet pressure low
Arr Inlet pressure sensor rnout voltage hrgh
Arr Inlet pressure sensor Input voltage low
Baro. pressure sensor Input voltage high
Baro. pressure sensor input voltage low
Coolant pressure low
Coolant pressure sensor Input voltage hrgh
Coolant pressure sensor Input voltage low
Coolant temp. hrgh
Coolant temp. sensor input voltage hrgh
Coolant temp. sensor input voltage low
Coolant level low
Coolant level sensor Input voltage hrgh
Coolant level sensor Input voltage low
Engine overspeed with engrne brake
ECM battery voltage hrgh
ECM battery voltage low
Arr temp. sensor Input voltage high
Arr temp. sensor Input voltage low
Exhaust temperature hrgh
Exh. temp sensor Input voltage hrgh
Exh. temp. sensor input voltage low
Fuel temperature high
Fuel temp. sensor input voltage hrgh
Fuel temp. sensor Input voltage low
p175 0
p1753
p175 4
pi87 3
pi87 4
pi87 7
PI90 0
~251 10
~251 13
so01 0
so01 1
so02 0
so02 1
so03 0
so03 1
so04 0
so04 1
so05 0
so05 1
SO06 0
so06 1
so07 0
so07 1
so08 0
so08 i
3009 0
3009 1
5010 0
so10 1
3011 0
$011 1
SO120
$012 1
$013 0
;013 1
so14 0
;014 ’
so15 0
;015 1
;016 0
;016 ’
GO203
;020 4
;021 0
to21 ’
,025 11
;026 3
,026 4
,026 7
44
14
15
12
l!
11
a5
61
7’
61
71
6’
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
71
61
73
81
a2
41
42
26
62
62
62
,040 3
,040 4
,040 7
62
047 0
047 1
048 0
048 i
049 0
049 1
050 0
050 1
051 3
051 4
052 3
052 4
053 3
61
71
61
71
61
71
61
71
31
31
31
31
62
E
DDEC System
Description
011temp high
011temp. sensor Inout voltage nigh
011temp. sensor Input voltage low
VSG sensor Inout voltage nrgh
vSG sensor Input voltage IOW
VSG swatch system not respondlnq
Engine overspeeo
Clock module abnormal rate
Clock module fault
Infector #l response time long
Injector #l response tcme short
Injector #2 response trme long
Injector #2 response trme short
Injector #3 response time long
Infector #3 response trme short
injector #4 response time long
InleCtOr #4resoonse time shot?
Injector #5 response time long
Infector #5 resoonse ttme short
Injector #6 response trme long
Injector #6 response trme short
Injector #7 response time long
Injector #7 response time short
Injector ffa response time long
Injector #6 response time short
Injector #9 response time long
Injector #9 response trme short
Injector #lO response trme long
Injector #IO response time short
Injector #I 1 response trme long
Injector #ll response time short
Injector #I2 response time long
Injector #12 response time snort
Injector #13 response time long
Injector #13 response time shor:
Injector #14 response ?ime long
Infector #14 response trme shor;
Injector #15 response time long
Injector #15 response time snort
Injector #16 response trme iong
Infector #i6 response time shor
Duel fuel BOI input voltage higr
Duel fuel BOI Input voltage low
Too many SRS (mlssrng TRS
Too few SRS (mrsstng SRSi
Aux engrne shutoown #I input active
Aux. Output ii1 short to battery (+)
Aux. Output #l open clrcult
Aux. Output #l Mech. System not responding
properly
Aux Output #2 short to battery (+)
Aux. Output #2 open crrcurt
Aux. Output #2 Mech. System not resoondrng
properly
Injector #17 response time long
Injector #17 response trme short
Injector #la response time long
Injector #la response time short
Injector #19 response trme long
Injector #19 response trme short
Injector #20 response trme long
Injector #20 response time short
Aux. Output #3 open crrcuit
Aux Output #3 short to ground
Aux. Output #4 open crrcurt
Aux. Output #4 short to ground
Aux. Output #5 short to battery (+)
DETROIT
DIESEL
2000 Warranty
Information
For
@
Series 50 ®and 60 ® Engines
ConstructionIndustrialCommercial
Marine Applications
ATTENTION
This booklet contains emission control systems maintenance and warranty
informationfor engines certified to U.S. EPA and CaliforniaNonroad Emission
Regulations.
It also providesthe Starting Date and Hours(Same as EquipmentDelivery Date
and Hours) of yourwarranty.Keep it with the equipmentand make it available
to any DetroitDiesel Corporation(DE)C) Dism'butoror Authorized Service Dea_er
if warrantywork is needed.
For Detroit Diesel Engines delivered outside the United States and Canada,
applicableproductwarranties and registrationinformationis availablefrom the
nearestDetroitDiesel OverseasDistributionCorporationDistributoror Authorized
Service Dealer if warrantywork is needed.
ENGINE SERIAL NO.
ENGINE MODEL NO.
DATE OF DELIVERY
HOURS AT DELIVERY DATE
WARRANTY REGISTRATION
(PLEASETYPE OR PRINTLEGIBLY)
SERIES 50_ AND 60•
CONSTRUCTION/INDUSTRIAL EQUIPMENT AND COMMERCIAL MARINE APPLICATIONS
Owner's Name
Street Address
City
State/Prey.
Zip/PostalCode
DetroitDiesel EngineSerial No.
Delivery Date .
Model No.
Make of Equipment
EquipmentIdentificationNo.
CustomerSignatureacknowledgesreceiptof
WarrantyInformationBooklet19SE490 (0001)
Date
iMPORTANT:TO REGISTER YOUR ENGINE, PLEASE COMPLETE AND MAIL THIS CARD TO DETROIT DIESEL
CORPORATION.
I TABLE OF CONTENTS
PAGE
INTRODUCTION...................................................................................................
2
SERIES 50_ AND 60e CONSTRUCTION/INDUSTRIAL
AND COMMERCIAL MARINE WARRANTY........................................................
3
EMISSION CONTROL SYSTEMS INFORMATION
2000 Federal EmissionControlSystemsWarranty..........i ..........................
6
California Emission Control Warranty Statement ........................................
7
U.S. Clean
9
Air Act ........................................................................................
Explanation of Owner's Maintenance Services ...........................................
10
Owner's Emission Control Maintenance Service Chart ..............................
13
LUBRICATING OIL ANALYSIS --WARNING VALUES .....................................
11
POLICY ON OWNER SERVICE ..........................................................................
12
CUSTOMER ASSISTANCE .................................................................................. 13
DETROIT
DIESEL
_
13400OuterDrive,West/Detroit, Michigan48239-4001
Telephone: 313-592-5000
www.detroitdiesel,com
1
INTRODUCTION
An Important Message to
Detroit Diesel Corporation
Product
Owners...
This booklet contains warranty information applicable to the engine you have
purchased.To register your engine, please complete and mail the enclosed Warranty
Registration Card.
Your engine is covered by the Detroit Diesel product warranty. In addition, your engine
may be covered by an emissionswarranty specified by either the U.S. Environmental
Protection Agency or the California Air Resources Board for engines certified to the
2000 nonroad emission standards. If you are not certain if the emission warranty
applies to your engine, check the Important Engine Information label located on the
rocker cover. Engines whichare excluded from certification due to either horsepower
rating, application, stationary usage or export will be so identified (see below).
OPTION LABEL
Computerized, polyester laminated engine option labels are attached to the valve
rocker cover(s). These labels contain the engine serial number and model number
and, in addition, list any optional equipment used on the engine.
With any order for parts, the engine model and serial number must be given. In
addition, if a type number is shown on the option label covedng the equipment
required, this number should also be included on the parts order.
Power takeoff assemblies, torque converters, hydraulic madne gears, etc. may also
carry their own name plates. The model and serial number information on these
plates is useful when ordedng parts for these assemblies.
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i
I
LIMITED WARRANTY ON NEW DETROIT DIESEL
SERIES 50 e AND 60 e ENGINES USED IN THE
APPLICATIONS AS OUTLINED BELOW
I
I
TERMS OF COVERAGE
Uses
This warrantyapplies tothe first retailpurchaser and subsequent owners duringthe
WARRANTY PERIOD of new Detroit Diesel Sedes 50 and 60 Enginesincludingthe
Detroit Diesel marine transmissionsuppliedand used incombinationwiththe engine
in commercialmarine applications(referred to as Engine) and attached raw water
pump, alternator, air compressor,starting motor, alternator and hydraulicpump
(referredtoas Accessories)manufactured or suppliedby DetroitDiesel Corporation*
(referredto as DDC) which are used in the applicationsshownbelow.
Defects
This warrantycoversEngine REPAIRS to correct any malfunctionoccurringduring
the WARRANTY PERIOD resultingfrom defectsin matedal or workmanship.
Repairs
To obtain warranty repairs, you must request the needed repairs within the
WARRANTY PERIOD from an authorized DDC service outlet. Only new genuine
parts or remanufacturedparts or componentssuppliedor approvedby DDC willbe
used.DDC may, at its discretion,replace ratherthan repaircomponents.A reasonable time must be allowed to perform the warranty repair after taking the engine to
the authorized service outlet. Repairs will be performed dudng normal business
hours.
The owner is responsible for the percentage of repair costs shown in the
WARRANTY PERIOD chart.
APPUCATION
WARRANTYPERIOD
WARRANTY
WARRANTYUMITATIONS ADJUSTMENT
CHARGETO
WHICHEVER
RRSTOCCURS BEPAIDBYTHEOWNER
MONTHS ENGINE
HOURS PARTS
LABOR
Series
50and60
Co_n/Industdal and
Commercial
MarineApplica_ons
Accessories
Block_
Crankshaft
and
Connecting
Rods
Series50and60
Agricultural
Machinery
Applications
Accessories
0072
NoLimit
NoCharge
NoCharge
0-12
0-2,000
NoCharge NoCharge
Upon
ex_wation
oftwe/ve
(12)rnon_
wan_nly
coverage,
but
12,000
hours
ofuse,thewan_nty
conlJnues
toapply
asfallows:
13_6
0-12,000
NoCharge
100%
0-36
002,$00
NoCharge
NoCharge
0°12
002,000
NoCharge
NoCharge
LIMITED WARRANTY ON NEW DETROIT DIESEL
SERIES 50 e AND 60 ®ENGINES USED IN THE
APPLICATIONS AS OUTLINED BELOW (Cont'd)
Warranty Period
The WARRANTY PERIOD begins on the date the Engine is delivered to the first
retailpurchaseror put in use priorto sale at retail,whicheverdate occursfirst, and
ends at the [;il,_ or hoOFIFiTlitS
shownin the_WARRANTYPER[OD-c_6n
the preceding page.
Service Supplies
The cost of serv/ce supplies such as coolant, oil and filters which are not reusable
due to warranted repairs is covered by this warranty.
Engine Removal and Reinstallation - Construction/Industrial Applications
Reasonablelabor costs for engine removal and reinstallation,when necessaryto
make a warrantyrepair, are covered by this warrantyduring the first twelve (12)
monthsof service.
Mechanic's Travel Expenses
DDC will pay reasonabletravel expensesfor the repairingmechanicto travelto and
from the repairsite (dcck).
Like Replacement Engine
Engine(s)suppliedby DDC as a replacementfor an Engine stillunderwarrantywill
assumethe identityof the Engine being replaced and be entitled to the remaining
warrantycoverage.
THIS WARRANTY DOES NOT COVER:
Repairs Due To Accidents, Misuse, Storage Damage, Negligence or Certain
Modificatt'qns
....................
Repairs-duoto=an-accident;misuse, rrdsapp;[,_=tion,
storagedarnage,7'legligenceor
modificationexceedingDDC specifications,are notcovered by this warranty.
Engine Removal And Reinstallation - Agricultural Machinery, Stand-by Pump
and Commercial Madse Applications
Labor and material costsfor engine removaland reinstallation,when necessaryto
make a warrantyrepair are not covered by this warranty when the engine is in an
agriculturalmachinery,stand-bypump or commercialmarineapplication.
SERIES 50 ° AND 60 ®ENGINES USED IN THE
AS OUTLINED
I APPLICATIONS
LIMITED WARRANTY
ON NEW BELOW
DETROIT(Cont'd)
DIESEL
Non-DDC Supplied/Manufactured Components
DDC is not responsiblefor repair of componentsand/or assemblies which are
manufacturedor supplied by another manufacturer,such as non-DDC marine
transmissions,power take-offs and intake and exhaust systems. Such items are
coveredby the equipmentmanufacturer.
Maintenance
DDC is not responsiblefor the cost of maintenance or repairs due to lack of
performance of required maintenance services or the failure to use foel, oil,
lubricantsand coolant meetingDDC-recommendedspecifications.Performanceof
required maintenance and use of proper fuel, oil, lubricants and coolant are the
responsibilityofthe owner.See the Operator'sGuidefor full details.
Incidental or Consequential Damages
DDC is not responsiblefor incidentalor consequentialcosts or expenseswhichthe
ownermay incuras a resultof a malfunctionor failurecoveredbythis warranty,such
as communicationexpenses,meals, lodging,overtime,towing, and any associated
docking or harbor charges, loss of use of the Engine or equipment (=downtime"),
loss of time, inconvenience,cargo loss or damage, and other similar costs and
expenses.
i
Other Limitations
The performanceof REPAIRS is the exclusiveOwner'sremedy underthis warranty,
DDC does not aathodze any person to assume or create for it any other obligation,
or liability in connection with the Engine or the Accessories.
THIS LIMITED WARRANTY AND THE EMISSIONS WARRANTY ARE THE ONLY
WARRANTIES APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN
CONSTRUCTION/INDUSTRIAL, COMMERCIAL MARINE, AND AGRICULTURAL
MACHINERY APPLICATIONS. DETROIT DIESEL CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARPANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
DETROIT DIESEL CORPORATIONSHALL NOT BE LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE.
Some states do not allow the limitation of howlong this warranty may last or the liraitation or exclusionof incidentalor consequentialdamages, so the above may not
applyto you.This warrantygives you specificlegal rights,and you may also have
other rights which may vary from state to state.
"In Canadathe referenceis to DetroitDieselof CanadaLimited.
13400 Outer DriP, West / Detroll, M_::_igan
482_I
5
I
I
2000 FEDERAL EMISSION CONTROL SYSTEMS
I
WARRANTY COVERING DETROIT DIESEL ENGINES
NOTE: THIS SECTION APPLIES ONLY TO ENGINES CERTIFIED TO THE 2000
FEDERAL AND CALIFORNIA EMISSION REGULATIONS FOR NONROAD
ENGINES.
DetreitDlasaiCorpem_c,n-(E)BCywarrants-t_th_o_i,_,_ of_erfes 50 and_ODetroit
Diesel engines builtwith standard exhaust emissionscomponents,the engine (1)
was designed, builtand equippedso as to conform,at the time of sale, with applicable regulationsof the U.S. EnvironmentalProtectionAgency and the CaliforniaAir
Resources Board and (2) is free from defects in material and workmanshipwhich
cause the engine to fail to conform with those regulationsfor a period of five years
or 3000 hoursof engine operation,whicheveroccursfirst,or the new productwarrenty,if the productwarranty is longer.
The warrantyperiod shall begin on the date the equipmentis deliveredto the first
retail purchaseror, ifthe equipmentis firstplaced in serviceas a demonstratorpdor
to sale at retail, on the date EqeequipmentLsfirst placed in such service. Emission
related defects in the genuine DDC componentslisted below,includingreasonably
related diagnosticcosts, are coveredby thiswarranty.
WHAT IS COVERED
These componentsare covered by the above warranty.Some scheduled maintenance is required (refer to the Owner's Emission Control Maintenance Service
Chart).
• Fuel Injector,Electronic
* ElectronicEngineControls
WHAT IS NOT COVERED
• Conditions resultingfrom tampering, misuse, improper adjustment,alteration,
accident, failure to'use recommended fuel or non-porformance of maintenance
• The replacementof non-warranted maintenance parts;
• Consequentialdamages such as: less of time, inconvenience,economic loss, loss
of use of the engine or equipment;
• Any engine in equipment on which the hour meter reading has been changed so
that the mileage cannot be readily determined.
DETROIT DIESEL CORPORATION DOES NOT AUTHORIZE ANY PERSON TO
CREATE FOR IT ANY OTHER OBLIGATION OR LIABILITY IN CONNECTION
WITH THESE SYSTEMS. THIS WARRANTY IS IN ADDITION TO THE NEW
SERIES 50 AND 60 DETROIT DIESEL ENGINE WARRANTY FOR NONROAD
APPLICATIONS.
6
CALIFORNIA EMISSION CONTROL
WARRANTY STATEMENT-YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Detroit Diesel Corporation (DDC) are
pleased to explain the emission control system warranty on your 2000 engine. In
California, new heavy-duty off-road engines must be designed, built and equipped to
meet the State's stdogent anti-smog standards. Detroit Diesel Corporation must warrant the emission control system on your engine for the pedods of time listed below
providedthere has been no abuse, neglect or improper maintenance of your engine.
Your emiSSioncontrol system may include parts such as the fcel-injection system
and the air induction system. Also included may be hoses, belts, connectors and
other emission-relatedassemblies.
Where a warrantable condition exists, DDC will repair your heavy-duty off-road
engine at no cost to you includingdiagnc_Js,parts and labor.
MANUFACTURER'S WARRANTY COVERAGE:
The 2000 and later heavy-duty off-road engines are warranted for five years or 3000
hours. If any emission-related part on your engine is defective, the part will be
repaired or replaced by DDC.
OWNER'S WARRANTY RESPONSIBILITIES:
• As the heavy-dutyoff-roadengineowner,you are responsiblefor the performance
of the requiredmaintenancelistedin yourowner'smanual.DDC recommendsyou
retain all receiptscoveringmaintenance on your heavy-duty off-roadengine, but
DDC cannot deny warranty solelyfor the lack of receiptsor for your failure to
ensurethe performanceof all scheduledmaintenance.
• As the heavy-dutyoff-roadengine owner,you shouldhoweverbe awarethat DDC
may deny you warrantycoverageif yourheavy-dutyoff-roadengine or a part has
faileddue to abuse, neglect,impropermaintenanceor unapprovedmodifications.
• Yourengine is designedto operate on dieselfuel only.Use of any otherfuel may
resultin your engine no longer operating in compliance with California's emissions
requirements.
• You are responsible for initiating the warranty process. The ARB suggests that you
present your heavy-duty off-road engine to a DDC dealer as soon as a problem
exists.The warranty repairs should be completed by the dealer as expeditiously as
possible.
If you have any questions regarding your warranty rights and responsibilities, you
should contact Manager Service Operations at 1-313-592-5000 or State of California
Air Resources Board, RO. Box 8001, El Monte, CA 91731-2990.
WHAT IS COVERED:
These components are covered by the above warranty. Some scheduled maintenance is required (refer to the Owner's Emission Control Maintenance Service
Chart).
• Fuel Injector, Electronic
• Intake Manifold
• Turbocharger and Gasket
• Charge Air Cocter
7
• Electronic Engine Controls
CALIFORNIA EMISSION CONTROL
WARRANTY STATEMENT-- YOUR
WARRANTY RIGHTS AND OBLIGATIONS (Cont'd)
WHAT IS NOT COVERED
• Conditions resulting from tampering, misuse, improper adjustments, alteration,
accident,failureto use recommendedfuel or non-performanceof requiredmaintenarme
services;; .........
• The repfaceme_ of non-warrantedmaintenanceparts;
• Consequential damages such as: ices of time, inconvenience, economic loss, loss
of use of the engine or equipment;
• Any engine in equipment on which the hour meter reading has been changed so
that the engine's usage cannot be readily determined.
ADDITIONAL WARRANTY INFORMATION:
The warranty on emissions related parts is interpreted by the California Air
ResourcesBoard as fogows;
• Any warrantedpart scheduledfor replacement as requiredmaintenanceis warranted for the period oftime priorto the firstscheduledreplacementpointfor that
part. tf replaced or repairedunder warrantyprior to the first scheduled replacement of that part, the new or repairedpart shall be warrantedfor the time remaining to the first scheduledreplacement.
• The owner shallnot be charged for diagnosticlabor whichleads to the determinationthata warrantedpart is in fact defective,providedthatsuchdiagnosticwork
is performedat a warrantystation.
• The engine manufacturershallbe liablefor damagesto otherenginecomponents
caused by failure underwarrantyof any warrantedpart.
• Add-onor modifiedparts may not be used in the emissioncontrolsystem. Such
use_shall-begroundsfor-diseltowing-.a-warranty
clafm: The e,_g;,'_umanufacturer
-_si]_ii.ui. beltable to_tarrant_failrl=re_-ol-w_rranted
par_sc_used_y_i_u-s_eot such
an add-on Ormodifiedpart.
THINGS YOU SHOULD KNOW ABOUT THE
EMISSION CONTROL SYSTEMS WARRANTY
REPLACEMENT PARTS
The emissioncontrolsystemsof yournew DetroitDiesel Enginewere designed,built
and tested using genuineDDC parts* and the engine is certifiedas beingin conformity with applicable regulalJonsof the U.S. (Federal) EnvironmentalProtection
Agencyand the CaliforniaAir ResourcesBoard. Accordingly,it is recommendedthat
any replacementparts used for maintenanceor for the repair of emissioncontrol
systems be new, genuine DDC parts.
THE WARRANTY OBLIGATIONS ARE NOT DEPENDENT UPON THE USE OF
ANY PARTICULAR BRAND OF REPLACEMENT PARTS. THE OWNER MAY
ELECT TO USE NON-GENUINE DDC PARTS FOR REPLACEMENT PURPOSES.
USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY
MAY IMPAIRTHE EFFECTIVENESS OF EMISSION CONTROL SYSTEMS.
8
THINGS YOU SHOULD KNOW ABOUT THE
EMISSION CONTROL SYSTEMS WARRANTY (Cont'd)
If other than genuine DDC parts are used for maintenance replacements or for the
repair of components affecting emission controls, the owner should assure himself/herself that such parts are warranted by their manufacturer to be equivalent to
genuine Detroit Diesel Corporation parts in performance and durability.
MAINTENANCE AND REPAIRS
MAINTENANCE AND REPAIRS CAN BE PERFORMED BY ANY QUALIFIED
SERVICE OUTLET: HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED
BY AN AUTHORIZED DETROIT DIESEL CORPORATION SERVICE OUTLET.
Receipts covering the performance of regular maintenance should be retained in the
event questions arise concerning maintenance. These receipts should be transferred
to each subsequent owner of this equipment. Detroit Dieset Corporation reserves the
right to deny warranty coverage if the required maintenance has not been performed.
However, this decision would not be based solely on the absence of maintenance
records. Repairs covered by this warranty will be made at no charge by an authorized Detroit Diesel Corporation Service Outlet.
* "GENUINE DDC PARTS"when used in connection with Detroit Diesel Engines means parts
manufactured by or for Detroit Diesel Corporation, designed for use on Detroit Diesel Engines
and distributed by Detroit Diesel Corpora_on. This definftion includes remanufactured assembties designated reliabil_ and sold by authorized Detroit Diesel Corporation Distributom that
may be used in performing warranty repairs.
U.S CLEAN AIR ACT
U.S CLEAN AIR ACT
The U.S. Clean Air Act requires the engine manufacturer to furnish, with each new
diesel engine to be installed in nonread equipment, written instructions for proper
maintenance and use of the equipment or engine by the ultimate purchaser. The
instruction
shall correspond
to regulations
which the Administrator
of the
Environmental Protection Agency (EPA) shall promulgate. This booklet provides
these instructions to owners in compliance with the law.
NORMAL ENGINE USE
The owner's maintenance instructions contained in this booklet are based on the
assumption that the engine will be used to power nonread equipment which will be
used as designed:
• To operate within the specifications as provided by the equipment manufacturer,
• To operate on a daily basis, as a general rule, for at least several hours,
• To operate on specified fuel and lubricating oils as covered in the Owner's/
Operator's Manual,
Unusual operating conditions wig require more frequent engine maintenance as
specified in the Section =Explanation of Owner's Emission Control Maintenance
Services."
9
MAINTENANCE OF
SERVICES
J EXPLANATION
OWNER'S EMISSION CONTROL
The following explanation of emission control maintenance items and service
interval has been keyed, by number, to corresponding line numbers in the following
maintenance chart. More frequent maintenance will be required where an engine is
operated underother than normaJconditions(e.g., heavy dust, excessiveidle)-.
1. FUEL FILTERS:Replace thefiitem or filterelementsinthe strainerand thefilter
every300 hours, or when pluggingis indicated.Checkfor leaksafter servicing.
*2. FUEL INJECTORS AND VALVE LASH - DETROIT DIESEL ELECTRONIC
FUEL INJECTION SYSTEM: Check injectortiming and valve lash.The injector
timingand valve lash shouldbe checkedand adjusted,as specified.Whenever
an engineperformsin sucha manner thate fuel injectorproblemis suspected,
the fuel injectorsshouldbe removed,inspectedand corrected,as required.
3. CRANKCASE BREATI-IER ELEMENT: The crankcase breather element
locatedinsidethe valve coveror assembledat the frontof the gear case should
be removed, cleaned and reinstatiedevery 24 months.
4. DR¥'I'YPE AIR CLEANER: Under no operatingconditionsshouldthe intake
restriction exceed 20 inches of water (5 kPa) at full load and rated speed. A
clogged air cleaner element will cause excessive intake resection and a
reduced air supply to the engine. For equivalent restriction limits for lower
engine speed, refer to Detroit Diesel Corporation Engineering Bulletin No. 39,
=AirCleaner Systemsfor DetroitDiesel Engines."
Inspectthe air cleaner element every 150 hoursor more often if the engine is
operated under severe dust conditions.Replace the element if necessary.
Check the gaskets for deterioration and replace, if necessary. If the air cleaner
is equipped with an aspirator, check for aspirator damage or clogging. Clean
and repair as necessary.
5. ENGINE LUBRICATING OIL: Change the lubricating oil every 150 hours; the _
independent oil supplier (based on used oil analysis). See LubricatingOil
Analysis -- Warning Values, Page 12 (Refer to Fuel & Lubdeatiog Oils for
Detroit Diesel Engines7SE270).
6. ENGINE LUBRICATING OIL RLTERS: Install new lubricating oil filter elementsat each oil change or at a maximumof 500 hours,whicheveroccursfirst.
7. COOLANT: Checkthe coolantleveldailybeforestartingthe engine.Make sure
coolant is up to the proper level. Add coolant as necessary. DO NOT
OVERFILL. Check all coolingsystem lines and hoses for damage, leaks, or
loose connections.Tighten or replace as necessary (Refer to Coolant for
Detroit Diesel Engines, 7SE298). Check for proper inhibitorlevel at each oil
change(150 hours)and add as required.
8. THERMOSTAT: Check thermostatsand seals annually(preferablyat the time
the coolingsystem is preparedfor winteroperation).Replace the seals and/or
thermostat, if necessary.
*9. TURBOCI-IARGER: Inspect turbochargermounting, air intake and exhaust
ducts and connectionsfor leaks daily.Check the oil inlet and outlet lines and
connectionsfor leaks and for restrictionsto oil flow.Check for unusualvibration
or noises.If excessive,removethe unitfrom serviceand have cause corrected.
*Anemissioncontrolservice.
10
OWNER'S EMISSION CONTROL
MAINTENANCE SERVICE CHART
OWNER'S EMISSION CONTROL MAIN33ENANCESERVICE CHART
No.
t
MAINTENANCE SERVICES
1
FuelF31te_
2
Irf_ctors&ValveLash* DI)EC
3
Crankcase
BreatherE[ernent
4
AirCleanerBement
5
EngineLubncadng
Oil
6
EngineLubric_ngOilFilter
7
Coolant
8
"_etr_s_t & Sea_
g
Turbocharger
_-Refer{opageg _r deta_
lllainter_m:eepera_ons:
• Checkleveldaily.
R - Reptace
f - Inspect,Correct
C -Clean
D - Ded]y
@ Coolantmustbe_
_or
ploperinhibitorlevel.Inhibitor
mustbeaddedasrequired.
LUBRICATING OIL ANALYSIS - WARNING VALUES
A fuel dilution exceeding
2.5% by volume indicates
an immediate
need for an oil
change and corrective
maintenance
action, Fuel dilution can be confirmed
by ASTM
D322 test procedure
performed
by oil suppliers or independent
laboratories,
In addition
Engines,
to the
has been
above
considerations,
exceeded
the
oil drain
interval
for
Detroit
Diesel
if:
1.
The viscosity at 102 ° F (40 ° C) of a used oil sample is 40% greater than the viscosity of the unused oil measured
at the same temperature
(ASTM D445 and
D2161).
2.
The iron content
3.
The pentane insolubles
(total contamination)
D893), carbon (soot) content, TGA exceeds
exceeds 1.00% by weight (ASTM
1.5% by weight (ASTM E1131 ).
4.
The total
D2896).
1.0
base
is greater
number
than
(TBN)
100 parts
per million.
is less than
11
(ASTM
D664)
or 2.0
(ASTM
POLICY ON OWNER SERVICE
MAINTENANCE SERVICES -- Propermaintenanceand care of the engine willhelp
achievelowerovera, operatingcosts.Use of recommendedfuels and lubricantsand
regular maintenanceperformed by competent service personnelwill help avoid conditionsadsing_rom.neglectwhich are not.ceveredby DetroitDiese_Ce_pors£1on
new
productwarranties.The maintenanceservicesdescribedin theapplicableOperator's
Guide shouldbe performedat t_e time and/or mileageintervalsstated, byan authorized DetroitDieselCorporationService Outletor any qualifiedserviceoutlet.
PRODUCTION CHANGE -- DetroitDiesel Corporationreservesthe right to make
change(s) indesignor add imprevement(s)on the productsat any timewithoutincurring any obligations to install same on products previouslypumhased. Authorized
Service Outlets reserve a similar right.
WARRANI"Y REPAIR ORDER -- For the owner'srecords,the AuthorizedService
Outlet will providea copyof thewarranty repairorder listingall warrantyrepairs performed.
12
CUSTOMER ASSISTANCE
The satisfactionand goodwill of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel
Corporation and its authorized service
outlets,
member of management. If you have
already discussed the problem w'rththe
Sales or Service Manager, contact the
General Manager. If your problem originates with a Dealer, explain the matter to
As an owner of a Detroit Diesel engine,
you have a complete network of over
2,000 Detroit Diesel Corporation service
outlets in the U.S. and Canada, plus
a management member of the
Distributorship with whom the Dealer
has its service agreement.
many
worldwide
thatyour
are parts
prepared outlets
and anxious
to meet
Step
and service needs:
. Service by trained personnel,
When it appears that your problem cannot readily be resolved at the distributor
level without additional assistance, contact the Detroit Diesel Corporation
Regional Product Support or Operations
Manager responsible for your local distributor. You will be assisted by a mem-
- In many areas, emergency service 24
hours a day.
• Complete parts support, including
raliabilP components,
• Sales teams to help determine your
power requirements,
• Product information and literature.
Two
ber of the Manager's staff depending
upon the nature of your problem.
Identify the U.S. regional area from the
map on the following page.
We recognize however, that despite the
best intentions of everyone concerned,
misunderstandings may occur. Normally,
any such situation that arises in connection with the sale, operation or service of
your engine will be handled by the
authorized service outlet in your area
(call or check the Yellow Pages for the
Detroit Diesel Corporation service outlet
nearest you).
To further assureyourcomplete satisfaction, we have developed the following
procedureto be followedin the eventyou
have a problemthat has not been handied satisfactorily.
Step One
Discussyour problemwith a member of
management from the authorized service outlet. Frequently, complaintsare
the resultof a breakdownin communication and can quickly be resolved by a
13
Eastern Region
Regional Product Support or
Operations Manager
187 Monmouth Park Highway
W. Long Branch, N.J. 07764
Phone: (732)222-1888
Fax: (732) 222-3411
Southeastern Region
Regional Product Support or
Operations Manager
5111 BewdenRoad
Jacksonville,FL 32216
Phone:(904) 448-8833
Fax: (904) 448-24tl4
Central Region
Regional Product Support or
Operations Manager
13400 Outer Drive, West
Detroit,MI 48239-4001
Phone: (313) 592-5990
Fax: (734) 762-1032
i
Ik =_._
_w_
Southwestern Region
Regional Product Support
or Operations Manager
2711 LBJ Freeway,Suite 1036
Dallas, TX 75234
Phone: (972) 247-4313
Fax: (972) 247-4316
Prior to this contact, have the following
informationavailable:
° Name and locationof authorized
service outlet.
• Type and make of equipment.
• Engine model and sedal number.
• Engine delivery date and accumulated hours of operation.
Western Region
Regional Product Support
or Operations Manager
10645 StudebakerRd.
Downey,C_
..........
Phone: (o_z} 9z_/Ul_
• Nature of the problem.
• Chronologicalsummaryof engine's
history:.......................
Fax: (562) 864-0502
Step Three
Canada
Regional Product Support
or Operations Manager
DetroitDiesel of Canada, Ltd.
150 Duffedn Ave., Suite 701
London, Ontario N6A 5N6
Phone:(519) 661-0149
Fax: (519) 661-0171
If you are still not satisfied present the
entire matterin wdting or byphone to:
Vice President, Customer Assurance
DetroitDiesel Corporation
13400 Outer Drive,West
Detroit,MI 48239-4001
Phone:(313) 592-7357
Fax: (313) 592-5906
Website:www.detroitdiesel.com
When contactingthe Regional or Home
Office, please keep in mind that
ultimately your problem will likely be
resolved at the service outlet utilizing
their facilities, equipment and personnel.
Therefore, it is suggested that you follow
the above steps in sequence when
experiencing a problem.
14
WARRANTY CLAIM RECORD
DATE
ENGINEHOURS
WARRANTYSERVICEPERFORMED
15
WARRANTY CLAIM RECORD
DATE
ENGINEHOURS
WARRANTYSERVICEPERFORMED
16
I
MAINTENANCE RECORD
DATE
ENGINE HOURS
MAINTENANCE SERVICEPERFORMED
17
I
MAINTENANCE RECORD
DATE
ENGINE HOURS
I
MAINTENANCE SERVICE PERFORMED
18
DETROIT
com._.o.DIEEEL _®
13400 Outer Dd_e, west / Detroit, Michigan 4_239-4001
T_e_
313-_2_
www detroitdiesel corn
Delmit Diesel _d the SpinningArrows Design°, Series 60* and Series 50• are registered trademarks of Detroit Diesel Corporation.
"Ig_E4SO 0001 ©2I)(_ DETRO_ DIESEL CORPORATION.
Printed in U.S.A.
DETROIT
DIESEL
Series 60 DDEC IIIDriving
"lips
• STARTING THE DDEC III ENGINE
Before starting the engine, make sure you keep your foot off the throttle
pedal, The Series 60 is already electronicaily timed and fueled for
optimum starting. Starting the Series 60 is extremely easy. First make
sure the transmission [s in neutral. Now turn the ignition switch to the
"On" position. Notice that the yellow "Check Engine," red "Stop Engine"
and optional cruise control lights illuminate for several seconds, then go
out. DDEC diagnoses its own engine electronics with warning light.
If the check engine light stays on, or does not come on at all, notify
your maintenance department or your nearest Detroit Diesel service
outlet as soon as possible. DDEC Ill improves cold starting by sensing
oil, coolant and air temperatures and adjusting the injection and timing
automatically. This lets the Series 60 start at 20 to 25 Fahrenheit or 11
to 14 Celsius degrees lower outside temperature
than a mechanically
governed engine without block heaters or ether. At high efevations and
cold temperatures, the engine may require a couple of 15 second
cranking periods before the cylinders start fidng. Remember: Give the
starter motor a 15 second rest for every t 5 second cranking period.
Low oil temperature will cause the electronic control meduie to preset
idle up to 950 RPM. As the oil temperature increases, the electronics will
adiust engine timing and gradually reduce engine speed to 600 RPM.
• CHECKING THE OIL LEVEL
Atlow the truck to sit for 15 minutes before pulling the dipstick. There are
6 quarts between "Low" and "Full." Only add 4 quarts at a time i_fthe
stick reads "Low." That way you wilI never overfill the sump.
• ACCELERATING THE TRUCK
Engine response versus pedal movement may feel different from the
mechanical governed engine you were ddving. The electronic foot pedal
assembly was designed to communicate "percentage" foot pedal travel
to the engine's electronic control module. The engine will respond
accordingly to the driver's demand.
Another throttle orgovernor characteristic you may need some time to
get used to is the DDEC limiting speed governor. This allows the driver
to command total engine response between idle and rated speed, such
as accelerating at half throttte -- an advantage when driving under
slippery conditions.
If you do require wide open throttle engine response, either
accelerating or just plain pulling hard, the throttle will have to be held to
the floor. TO obtain 100% fueling at any speed, the foot pedal will have
to be maintained at the fully depressed position.
• CRUISE CONTROL
For added driver convenience and comfort, DDEC Ill also features a
cruise controloption which works jusl like the system in your car. It can
be operated in any gear above 1100 RPM and road speed faster than 20
MPH. up to the rated engine speed. And it can be spoc'd to hold your
road speed at or below the maximum vehicle speed. "-he switch to
energize cruise control is usually mounted on the instrument panel Turn
the switch to the _ZQ
position to energize the system. When you reached
your road speed, press the _t switch to activate cruise control. The
cruise light will come on. To increase road speed in one MPH
increments, press the resume/acoel switch. To reduce road speed, press
and hold the set/coast switch until the lower speed is reached. Cruise
control is deactivated by slightly depressing the service brake, clutch
pedaI, or trailer brake. Also, the on/off switch deactivates cruise control.
Cruise control will maintain speed even on upgrades, unless power
requirements demand a downshgt. And, of course, cruise control doesnt
limit your speed on down grades.
25ST161-_
9403
Most likely, the cruise control will feel stronger than driving with the
response. That is why cruise control use is not suggested during slippery
driving conditions.
Use cruise control after down shifting on a hill to pull the hill Hitting
the resume switch (not the set switch) will keep the truck accelerating in
the lower gears up to rated engine speed
Cruise control will disengage below 1100 RPM or 20 MPH road
speed. When using cruise control, and you want 1opull the engine below
1100 RPM, remember to held the throttle pedal to the floor to keep the
engine pulling at wide-open throttle. Realistically, the engine will pull to
about 1050 RPM Remember, the electronic data programmed into the
ECM will not allow you to hurt or oveffuel the engine at low or lug engine
speeds. There is enough oil pressure to withstand hard pulls at low
engine speeds.
• ENGINE BRAKES
if your engine is equipped with both cruise control and an engine brake,
the engine brake will operate automatically while you are in cruise
control. The engine brake will come on "low" when your road speed
increases a few MPH above your cruise set speed, if your speed
continues to increase, the ECM will increase the engine's braking power
progressively. When the vehicle returns to the set cruise speed, the
engine brake will "turn off" until the next time you need them. For safety
reasons, don't use cruise control when it's not possible to keep the
vehicie at constant speed due to winding roads, heavy traffic...slippery
roads...or when descending grades that call for engine brake
assistance.
• SHIFTING
Depending on your transmission model, the gear split may vary from 500
RPM to 300 RPM. The electronic governor provides almost no overrun
capability, and ff the transmission is downshifted too early, you will
experience a temporary loss of pulling power until the engine speed falls
below rated speed. In general, when using a 7 or 9-speed transmission.
you sbeuld always downshgt between 1250 and 1300 RPM. This is true
even on steep grades with heavy loads. When using an 18, 15 or 13
speed transmission, you will need to downshift at an RPM that allows
"less than rated" RPM before throttle application in the next gear down.
You may.want_oJimit_engi_e speed-to J.9ooq_PJVl4_LLgea_s,-_he ......
Sedes 80 provides constant horsepower from t8B0_RPM thcough 2100
RPM but fuel economy is not as efficient above t 800 RPM.
If you decide to drive at CowerRPMs for improved fuel economy, don't
let different engine noises throw you off guard. The Sedes 60 sounds
quiet at 1400 RPM. almost as if it had quit pulIing. Don't believe it[ [f you
had a boost gage to look at while driving, you would notice the
turbocharger maintaining steady intake manifold pressure, even as
RPMs fall Depending on the air intake arrangement, you may also
experience a chuffing sound as the engine starts to pull hard at the lower
RPMs. This is caused by the velocity changes of the air flow within the
air intake plumbing. Electronic engines can actually deliver more fue_at
lower engine speeds than at rated speed.
• IDLING
The common belief, that idling a diesel engine, causes no engine damage
is wrong. Idling produces sulf_dc acid which breaks down the oil and eats
into bearings, dngs, valve stems and engine surfaces. If you must idle the
engine for cab heat or cooling, the _
idle function of the cruise control
switches should be utilized. An idle speed of t 100 RPM should provide
enough cab heat at zero degree ambient temperatures. A wthter front may
be used to improve cab heating while idling, but it should never cover
more than 3/4 of the gdll while driving. Winter fronts should only be used
when the ambient temperature remains below 10°F (-12.2°C).
\,
ROIT
DIESEL
Custom PaNs Catalog
TR/'rMD 150/180 AIR START UNIT
ENGINE SERIES NUMBER:
60
ENGINE MODEL NUMBER:
6063TK33
STEWART & STEVENSON
GENERAL INFORMATION
This customized parts catalog contains
inforrnationspecific to the customer serial
number. All engine components in this
catalog are divided into major groups of
functionallyrelated parts. A listing of the
groupsand their sub-groupsappears under
=GroupNomenclature"of this section.
The data in this publication is based on
information Imown to Detroit Diesel at the
time of printing.While every care and effort
has been taken to ensure the accuracyof all
information, engine modifleations or
subsequent engineering changes or
enhancements may cause certaindata to be
The AlphabeticalIndex is particularlyhelpful
when only a part name is known and the
groupcan not readily be determined. Parts
superseded or rendered obsolete. Detroit
Diesel reservesthe right to make changes
to this catalog at any time withoutnotice.
are listed alphabetically by noun name,
followedby a descriptionof the application
of the partand the final grouplocation,
If additional assistance is needed please
contact your authorized
Detroit Diesel
service outleL
Unlike the normal parts catalog this book
does not contain types. The listingof parts
is separatedonly by a group idantit_cation
(e.g.
1.1000
for
cylinder blocks).
Componentsof major assemblieswill follow
the assembly. The order in which parts are
listed is the same as the normal parts
catalog,
IMPORTANT ENGINE INFORMATION
Also included in the last pages of this
catalog is a listing of various supplies
requiredto maintainyour engine.
Your engine sedal number should be kept
readily available. It can be used to identJ(y
your model as well as ALL sen/ice parts
including kits, sets, warranty information
and extended coverage available.
CUSTOMER
=
ASSISTANCE
The satisfaction
and goodwill
of the
owners of Detroit Diesel engines are of
primary concern
to Detroit Diesel
Corporation and its distributor/dealer
organizations.
As the owner of A Detroit Diesel
Product you have a complete
network
of over 2,000 Detroit Diesel service outlets in the U.S. and Canada, plus many
outlets worldwide that are prepared to
meet your parts and service needs:
I
t
\\
'\
,r"
,,
',
k
I°°'4
_J
EASTERNREGION
LongBranch,NewJersey
187 MonmouthPark Highway
WestLong Branch, NJ 07764
Phone:(732)222-1888
Fax:(732)222-3411
WESTERNREGION
Downey,California
10645 Studebaker Road
Downey,CA 90241
Phone:(562)929-7016
Fax:(562)864-0502
PACIFICREGION
Australia
47 First Street
Black Rock,Victoria 3193
Phone:(61)9589-0484
Fax:(61)9589-6858
SOUTHEASTERN
REGION
Jacksonville,Florida
5111 BowdenRoad
Jacksonville,FL32216
Phone:(904)448-8833
Fax:(904)448-2444
CANADIAN REGION
London,Ontario
DetroitDieselof CanadaLtd.
150 DufferinAve.,Suite701
London,ONN6A5N6
Phone:(519)661-0149
Fax:(519)661-0171
CENTRALREGION
Detroit,Michigan
13400OuterDrive,West
Detroit,MI48239-4001
Phone:(313)592-5990
Fax:(734)762-1032
LATIN AMERICANREGION
Miami,Florida
2277N.W.14thStreet
Miami,FL33125-0068
Phone:(305)637-1555
Fax:(305)637-1580
SOUTHWESTERNREGION
Dallas,Texas
2711LBJFreeway
Suite1036
Dallas,TX75234
Phone:(972)247-4313
Fax:(972)247-4316
ASIAN REGION
Singapore
No.1 BeneiRace
Singapore629923
Phone:(65)865-1911
Fax:(65)861-1618
EUROPE,MIDDLEEAST,
AFRICA(EMA) REGION
TheNetherlands
Ridderpoort9
P.O.Box4161
2980GORidderkerk
TheNetherlands
Phone: (31) 1804-10208
Fax:(31)1804-62062
MEXICO
DetroitDiesel-Allison
de
Mexico
Av.SantaRosa58
Col. Ampliacion Norte
SanJuanIxtacala,Tlanepantla
C.E54160,Edodo Mexico
Phone:(525)333-1802
Fax:(525)333-1870
DETROIT
Custom
DIESEL
Parts Catalog
ENGINE DESCRIPTION
TR/TMD150/180AIRSTARTUNIT
SERIES NUMBER:
60
MODEL NUMBER:
6063TK33
SERIES
60 PARTS
1.0000
CATALOG
ENGINE (LESS MAJOR ASSEMBUES)
1.1000 ....
ALPHABETICAL
5.0000
CYUNDER BLOCK
INDEX
COOLING SYSTEM
5.1000 ....
FRESH WATER PUMP
ALPHABETICAi
iNDEX
LIST
1.100OA ... AIR BOX DRAINS
1.2000 .... CYUNDER HEAD
5.1000A . .. FRESH WATER PUMP COVER
5.2000B ... THERMOSTAT
1.200OA ... ENGINE, LIFTER BRACKET
1.3000 .... CRANKSHAFT, OIL SEALS
ANDSTABILIZERS
5.20OOC... WATER BYPASSTUBE
5.3000B ... WATER CONNECTIONS
5.4000A... FAN
1.3000A...
5.5000A ... HEAT EXCHANGER OR KEEL COOUNG
CRANKSHAFT FRONT COVER
1.3000B.,. VIBRATION DAMPER
1.3000C ... CRANKSHAFT PULLEY
1.3000D ... CRANKSHAFT PULLEYBELT
1.4000A ... FLYWHEEL
1.500OA ...
1.5000B ...
1.6000 ....
1.7000 ....
FLYWHEEL HOUSING
FLYWHEEL HOUSING ADAPTOR
CONNECTING ROD AND PISTON
CAMSHAFT AND GEAR TRAIN
1.7000A ... BALANCE WEIGHT COVER
1.7000B ... ACCESSORY DRIVE
1.8000 ....
VALVE AND INJECTOROPERATING
MECHANISM
1.8000A ... ROCKER COVER
2.0000
5.6000A ... RAW WATERPUMP
5.70(_A ... WATER RLTER
6.0000
EXHAUST
SYSTEM
6.1000A ... EXHAUST MANIFOLD
AND/OR CONNECTIONS
62000A ... EXHAUST MUFFLER
AND/OR CONNECTIONS
6.60001 ...
7.0000
ELECTRICAL
INSTRUMENTS
7.1000A ... BATTERY CHARGING GENERATOR
73000A ... STARTING MOTOR
7.4000B ... TACHOMETER DRIVE
7.7000B ... THROTTLE AND GEAR CONTROL
FUEL SYSTEM
2-1000A ... FUEL INJECTOR
2.1000B ... INJECTOR CONTROLS ELECTRONIC
2.2000 .... FUEL PUMP
2.3000A ... FUEL FILTER AND STRAINER
2.4000A ... ALTERNATE FUEL SYSTEM
2.5000A...
FUEL LINES AND FUEL COOLER
SYSTEM
ELECTRONIC
7.700(_ ... CRT AND LCD DISPLAY
SYSTEM ELECTRONIC
7.8000(3 ... SPARK PLUG.IGNITION COIL,
WIRING HARNESS
8.0000
POWER TAKE-OFF
8.1000A ... POWER TAKE-OFF ASSY.
2.7000A ...
2.S000 .... INJECTOR CONTROLS
9.0000
2.9000A ... THROTTLE CONTROLS
11.0000
3.0000
AIR SYSTEM
3.1000A ... AIR CLEANERAND/OR ADAPTOR
3.300OA . .. AIR INLET HOUSING
TRANSMISSION AND PROPULSION
9.I000A ... MARINE GEAR
ENGINE
MOUNTING
11.1000A .. ENGINE MOUNTING EASE
12-0000
MISCELLANEOUS
12.4000A .. AIR COMPRESSOR
3.3000C...
AIR INTAKEMANIFOLD
12_5000A.. HYDRAULIC PUMP
3.4000 ....
BLOWER AND DRIVE
12.6000B.. AIR STAH!
3.400OA... BLOWER DRIVE SHAFT
3.5000A ... TURBOCHARGER
12.6000C .. COLD WEATHERSTARTING AIR KIT
12.7000A .. APPEARANCE PACKAGEPARTS
3.7000 ....
12JBO00A
.. SUPPLIES/MAINTENANCE PRODUCTS
4.0000
INTERCOOLER/AFTERCOOLER
LUBRICATING SYSTEM
4.1000A ... OIL PUMP
I_S000B.. FABRICATION MATERIAL
12.8000C .. SERVICE KITS AND SETS
4.1000B ... OIL DISTRIBUTION SYSTEM
4.1000C..,
4.2000A...
OIL PRESSURE REGULATOR
OIL RLII:::H
4.3000A...
OIL FILTER LINES
4.4000A...
OIL COOLER
4.5000A ... OIL FILLER
4.6000A ... DIPSTICK
4.7000A ... OIL PAN
4.8000A ... VENTILATING SYSTEM
6SP161_©
199_
DETROITDIESELCORPORATION
1--1
SERIES 60 PARTS CATALOG
ALPHABE77CAL
PART
NAME
GROUP
NO.
A
PART
NAME
BOE_
ACTUATOR
ASSEMBLY,
GEAR
7. 7460B
ACTUATORASSY.,NATURALGAS
2. 93S5A
ADAPTORK_, POWERTAKEOFF
1. 3281C
ADAPTOR,DIPSTICK
4. 60_0A
ADAPTOR,
FLYWHEELHOUSING
1.5130B
ADAPTOR,FUEL PUMP DRIVE
2. 2260
ADAPTOR,
HYDRAUUCPUMP
12.5020A
ADAPTOR,OIL COOLER
ADAPTOR,OIL RLTER COVER
4. 4110A
4. 2291A
ADAPTOR,
TACHOMETERDRIVECABLE
7.
ADAPTOR,TACHOMt: I=:HMOUNTING
12.8325A
ADAPTOR,WATERPUMP DRIVE
3. 7005
ADDffNE, CURING (THREADLOCK& RTV)
12.R,_A
ADDffNES, DIESEL FUEL
12.8280A
ADDITIVES,SUPPLEMENTALCOOLANT
AIRINTAKE
MANIFOLD
12.8260A
3. 3801C
INDEX
GROUP
NO.
M_FOU_
TOHEAD
6.1_
BOLT,,
_
COVER
BOOT/_ID SPRNG IGI'_TIGN
I. 8460A
7. 8_=C,
BRACKEI"GASVALVEMOUNTING
2. 4145A
EPACKEr IGNR'_N COIL
7. 8705C
_
OL F'0..I.,ER
_
CU_MP
4. 5004A
BRA_,
ACIUA'rOR& TI..RUI/LE BODY
2._
BRACI<E_,
AC'[UATORMOUNTING
2. 178_
_
AIR_
12.4010A
BRAC_
BOATSIJILDER_
B_,
BREA'R-]t_I
_
BRA_
EI._
MOUNTING
MODULE
PIPE
DIS'_
UNIT
BFIAC_, ENG_E I._ i=d.4- REAR
_,
ENGINELI=-iI_"I-FRONT
BRACKL_,F,_I BELT_
ASS_
2.15148
4. 818_.
2. 1-=z'v,_
_R
1._m_
1.2_(]A
5. 4342A
BRACKE'_,
FUB. RLTE_MOUNTING
2._
_
7. 1582A
GENERA'fORADJUSTINGS'P,N>
BRACKE_,GENB_ATORMO.It;/1NG
7. 1_5A
BRA_,
4. 41(X1_
AIRSTARTERASSY.
12.6080B
AIR STRAINER AND LUBRICA'I1ON ASSY.,
AIRSTARTER
12-6120B
BRA.C;'_-_,
OE.PUMPSCREENSUPPORT
4. 1540B
APPEARANCEPACKAGEPARTS- SECTION1
12.7001A
BRACKE_,PLmJERSE
C:F'ARMOUN11NG
9. 1011A
APPEARANCEPACKAGEPARTS- SEC'RON3
12._
BRACIng, SMEFMODULEMOUNTING
2. _-=__-_-_-
APPEARANCEPACKAGEPARTS - SECI'ION5
12.7005A
BRACKE_.STab'lINGMOTORSUPPORT
7. 3007A
ARMASSY.,EXHAUSTVALVEROCKER
1. 8060
_
WATER_
5. 708[_
ARMASSY.,INJECTOR ROCKER
1.8080
BUS_
FANB_LTIDLERPtY..t.EYSLIPP(DRT
ARMASSY.,INTAKEVALVEROCKER
1. 8075
BUSHING,INJECTORROCKER_
BI_
OILPUMPBODY
OILCOOI.B_I-lOUSINGSI.IPPORT
_
5. _348A
1.8110
4. 1050A
B
BAI.LANDSEATASSY, INJECTORROC_
AFIM
C
1.8090
BEARI_ ACCESSORYDRIVE
1. __7_-___
_
BEARING,AIRCOMPI_SSOR DRNE SHAFT
12A048A
CARCRANKSHAFI"
MAINBEARING
1.3110
BEAR1NG,
CAMSHAFT
1.7040
CAR,_
1.7042
_r.ARING,CYJ.ffCHPILOT
1. 4040A
CAROL RLLER
4. 50"IG_
BEhF_NG,FAN_
5. 4111A
C,NPt.UG_:_C$60
1.B043A
BF_.ARING,
FRESHWATE_PUMP
3. i_J
CHAIN,OILF_ I l=qCAP
4._
_
FUELPUMP
2.2060
_
3. 1280A
BEARING,PISTONPIN.
1.6142
O..AMI_,
INJECTOR
1.3_LO
CLAIRe,WA'I_R_
7. 1575A
(_
BLADE,FANHIGH LOWAND CP,ANKSN/Wr
MOUNTED
5. 4010A
CUR,AODtJSIIC,
AL
CU_,NR _
BLOCK,CYUNDER
1.1001
CI,J_,BREA_ _": TI,,_E
4. 804(_
BLOCK,
FU_ S¥,Sit:M _
2. 5250A
CUP,COt.D R.ATETO FII..3ER_
2. 5121A
BOD_,_
3.7190
CUR,_
2. 5180A
4. 1680C
4. 1040A
CI.._,[.,I_TIC_
CLR,R.Bn_ i= I.IOSE
4. 604_
12.85548
BOLT,,
CAMSHAFTBEARINGCAP
1.7046
CLJ_,FU_L DRAIN
2. _'_'_A
BOLT,,
_
1.3140
Ct_, OILRLTERLII_
4. 3045A
__=:_
X CRANKSHAFT
_
BELT,,
_TOR
DI::_
_
WA=m-_PUMP
BOD_OILPP,ESSUf_ _TOR
BO(_, O_ PUMP
A_ F_ _
MAINBEARINGGAp
_$PI6'1_0_ o ]_ DETROITD1ESE_
CORPO_
ASS_.
1.7001
_
AIRIM.ETPIPE_
2.1270#.
INLET_
5. 70_A
COOLANTS_t_R:M
12.8270A
WATB:t_
HF.ADN_ET
1. 7560A
1_
1-3
ALPHABETICAL
INDEX
PARTNAME
SERIES 60 PARTS CATALOG
GROUP
NO.
PART
NAME
GROUP
NO.
CUP, STRAINER TO FUELPUMP
2. 5070A
CLIP,TURBOCHARGEROIL RETURNTIJBE
3. 5507A
CLIP,TURSOCHARGEROIL SUPPLYTUBE
3. 5502A
CLIP,WATER BYPASSTUBE
S. 2190C
ELBOW,TURBOCHARGEFtAIR INLET
3. 1259A
CLIRWATER PUMP TO OILCOOLER TUBE
5. 3405[3
ELEMENT,FUEL RLTER
2. 3320A
CLUTCH ASSY.,FAN
5. 4112A
ELEMEN'E,FUEL STRAINER
2. 3010A
COIL IGNITION
7. 8710C
ELEMENT,OIL FILTER
4. 2250A
COLD WEATHERSTARTINGAID KIT
COMPRESSOR ASSY.,AIR
12.6301C
12.4001A
F:lFMENT,WATERRLTER
5. 7020A
CONNECTING ROD ASSY.
CONNECTION, FLEXIBLEEXHAUST
1. 6001
6. 2095A
CONNECTOR,
DEUTCH
2. 1850B
CONNECTOR,PERIPHERAL
CORE,OILCOOLERENGINE
2. 1580B
4.4001A
COUPUNG, AIR COMPRESSORDRIVE
12.4050A
COUPLING, FUELPUMP DRNE
2. 2230
COUPLING, HYDRAUUCPUMP DRIVE
12.5010A
COUPLING, WATERPUMP DRIVE
3. 7025
COVER_Y.
ACCESSORYORWEACOUSTICAL 1.754OA
DRIVEGEAR,AIR COMPRESSORDRIVEASSY
12.4072A
E
F
FILTI-_tASS_.,WATER
5. 7001A
RLTER UNI'I_,BREATHER
4. 8060A
Fi111NGS,FLEXIBLEHOSE END
12.8552B
FLYWHEELASSY.
1. 4001A
FORK,FUEL PUMP COUPLING
2. 2220
FUEL SYSTEM PRODUCTS
12.8006A
FUEL/AIRSEPARATOR
2. 3305A
.....
COVER ASS_., ROCKER
1.8450A
GAGE, AIR PRESSURE
12.8315A
COVER ACOUSTICAL
1.7530A
GAGE, AMMETER
12.8310A
COVER AIR COMPRESSOR DRIVEADAPTOR
12.4032A
GAGE, FUELPRESSURE
12.8355A
COVER BALANCEWEIGHT
1. 7470A
GAGE, FUELVOLUME
12.8350A
COVF_.RCAMSHAFTBEARINGCAP
1. 7037
GAGE, HOUR METER
12.8370A
COVER ENGINE FRONT ACCESSORYDRIVE
1. 3191A
GAGE OILPRESSURE - ENGINE
12.8330A
COVER FRESH WATERPUMP BODY
5. 1031
GAGE OIL PRESSURE- TRANSMISSION
12.8335A
COVER FUEL RLTER
2. 3390A
GAGE OIL TEMPERATURE
12.8340A
COVER FLIELSTRAINER
2.3080A
GAGE SP_Fr".OMETER
!2.83BSA
COVER GEAR CASE
1.3158A
GAGE TACHOMETER
12.8320A
COVER INJECTORHARNESS
2. 1702B
GAGE TURBOBOOST
12.8375A
COVER OIL FILLERHOLE
4. 5070A
GAGE VOLTMETER
12.8380A
COVER OIL PUMP
4.1220A
GAGE WATERTEMPERATURE
12.8345A
COVER TACHOMETERDRIVE
7. 4445B
GASKETKIT,CYLINDERHEADOVERHAUL
1. 200_
COVER THERMOSTATHOUSING
5. 2120B
GASKET _
1.10(_
COVER WATERRLTER
5. 7034A
GASKET,ADAPTORTO OILCOOLERHOUSING
4. 411?..A
COVER WATERPUMP
5. 123.5A
GASKL=_,
AIR COMPRESSORDRIVEHOUSING
12._
COVER WM=t::HPUMP INLET
3.7030
GASKE'I_,AIRCOMPRESSORMOUNTING.
12.4005A
COVER,FUEL PUMP
2. 2030
GASKE'_,AIRINTAI_ MANIFOLD
3. 3803C
CRANKSHAFT ASSY.
1. 3001
GASKET.AIRSTARTERMOUNTING
12.6085B
CYLINDER KIT
1. 6182
GASKE'_,BALANCEWEIGHT COVER
GASKEt, BREATHERSHELLCOVER
1. 7480A
4. 8057A
GAs_--T, CYLINDERHEAD COMPRESSION
GASKEI_,DIPSTICK
1. 2010
4. 6010A
GASKE'_,ENGINE FRONT ACCESSORYDRIVE
1.3192A
D
DAMPER, VIBRATION
1. 3210B
DIPSTICK
4. 6001A
DISC, FLYWHEELFLEXIBLECOUPLING
1.4075A
DRIVE ASSY.,ACCESSORY
1.7600B
DRIVEASSY.,AIRCOMPRESSOR
12,4030A
DRWEASSY, FUELPUMP
1 _4
2- 2240
ENGINE OVERHAUL
GASKE'_,EXHAUSTMANIFOLD
6. 101Oh,
GASKE"_,FRESH WATERPUMP
3. 7185
GASKL=T,FRESH WATERPUMP BODY COVER
3. 7195
GASKE'_,FUELPUMP COVER
2. 2040
6SPt61_
© 199_D_J'P.OIT
DLESEL
CO_OPJG'_OH
SERIES
60 PARTS CATALOG
ALPHABETICAL
PARTNAME
GROUP
NO.
GASKE'E,FUEL PUMP TO ENGINE OR DRIVE
PART
NAME
INDEX
GROUP
NO.
HEADASS_.,CYLINDER
1. 2001
2. 2007
HEAT_
6. 1171A
GASKE1 FUEL PUMP VALVEPLUG
2. 2180
HOSEASS_ ,aJRVB_TPJ_
2. 5530A
GASKE'I HOUSING ADAPTOR
GASI_"I HYDRAUUC PUMP
3. 7012
12.5005A
_
ASSY.,PRO-CHB< INLET
HOSEASS_.,PRO-CI-EK OUTLET
2. 5510A
2. F,_OP.A
GASKEt OILCOOLER ADAPTORTO BLOCK
GASKE'I OILCOOLER CORE-INNER
4. 4115A
4. 4030A
HOSE_,_R
_
LINE
HOSEHUMPADAPTORTO INT TUBE
2. I=_"_a.
2. 419P.A
GASKE1 OILCOOLER CORE-OUTER
4. 4040A
_
COLDPLATETO FLTER
2. 5116A
GASKE1 OILCOOLER HOUSING
4. 4055A
I',iO_E,COLDPLATETO RJB. RLTER
2. 5117A
4. 50BOA
HOSF_,FLTERTO _
GASKL=IOIL FILLERTUBE ADAPTOR
4. 5007A
_
FLEXIBLE
(BULK)
12 R'=_0B_
GASKE'I OIL PANTO BLOCK
4. 7030A
_
FLE__
2. 5215A
GASI(L='IOIL PRESSURE REGULATORBODY
4. 1730C
HOSE, _
GASK_='IOIL PUMP INLET PIPE
4. 1520B
HOSE,RJB. PUMPOLRLETTO COLDPLAIE
2. 5115A
GASKL=IOIL PUMP OUTLET PIPE
4. 15.cOB
HOSE,FUELPUMPOLm.ETTO RLTER
2. 5110A
C-,
-_ SKE1 ROCKER COVER
-,
1. 8455A
HOSE"FUELSUPPLY
2. 5009A
GASI<_J STARTINGMOTOR
7. 3004A
HOSE,GBqB:tATOR
_
7. 1012A
C-:-:-:-:-:-:-:-:-_S
KE"1TACHOMIci =:RDRIVECOVER
GASKE'I TURBOCHARGEREXHAUSTINLET
CONNECTION
7. 4447B
HOSE,OIL_
8. lgg0A
3. 5307A
HOSE,WATERBYPASSTUEE
5. 2165C
GASKE'_,TURBOCHARGEROIL RETURNTUBE
3. 5506A
HOSE,WATER_
5. 7090A
GASKE'_,WATERPUMP COVER
5. 12_,A
HOSF_,WAI'I_ RLt-'_R
O.II I.El"
5. 710(_
GAUGE, AIRPRESSURE METRIC
12.6140B
HOSE,WATERPUMPTO OILCOOLER
5. 3401B
GEAR ASSY.,ADJUSTABLECAMSHAFT IDLER
1.7221
HOUSING"a'SSY'_
1.5001A
GEAR ASSY.,HYDRNJUC MARINE
9. 1001A
_
1. 3156A
GEAR ASS_.,IDLER
1. 7220
HOOS_NG,
ACCESSORYDRIVE
1./or_.,Es
GEAR,ACCESSORY DRIVESHAFT
1. 7642B
_
12.40_6_,
GEAR,CAMSHAFT AND BALANCESHAFT
1. 7200
I-R)USI_IG,FANDRIVESPINDLE
5. 410_A
GEAR,CRANKSHAFT"I']MING
1. 3145
HOUS_G, OU.COOL_-ENGINE
4. 4(_OA
_,
1. 4010A
HOUSIN_
OL "/'P,
ANSR_ COCt,E_-FLTER
ADAPTOR
4+4053A
GEAR, PRESHWA', P_RPUMP DRIVE
5.1190
I,.IOUS_ _
3. 5(X_A
GEAR, FUEL PUMP DRIVE
2, 2087
_
GEAR, FUEL PUMP DRIVEN
2.2088
Ht.IB,AIR_
12.404(_
GEAR, HYDRAULICPUMP DRIVE
12.5030A
_
CAMSHAFTGEAR
1. 7206
GEAR, IDL[_R
1. 7222
I-MB,CRANKSHAFT
PULLEY
1. 3310C
GEAR, OIL PUMP DRIVE
4. 1090A
HUB,R.Y_ ;,-_-,-_
1.40e0A
GENERATORASSY.
7. 1001A
HUB,_
GOVERNOR KIT,AIR COMPRESSOR
GUIDE,
DIPSTICK
12.4305A
4.6020A
_
GUIDE,
EXHAUST
VALVE
1.8320
ASSEMBLY
OtLFILLER HOLE COVER
FLYWHEELRING
n. ENHAUST
M_NIFOLD
HEAD
RJb_ INLET
2. 5160A
2. 5060_
INLET
ASS_,GFJ_ CASE
AIRCOMPPESSORDFdVE
TURBINE
ADJUSTABLE
IDLERGF.AR
1. 7255
CCXJPLP_
GE/_R
1. 7250
IDLERGE/_RBEARING
1. 7228
I
H
-=,'r
IB.ER, FUtIEY FANBELTW_H ADJUSR_ ARM
7. 1905A
5. 4325A
12.8070A
iMP_ ! _=R,
FRESHWA1-B_FUM_
3.7200
1. B050
_,,_-G"[ORASS_
2. 1001A
_
7.8720(:;
_S_';
E_,-INJSTV/_,_E
1. R"_--
HARNESS"
ECM BOATBUILDERIN I_=HEa_E
MOOUU_
2. 16g0B
INSTAIJ.ATION
I_'_,WATI_ FILTER
5. 7010A
2. 1700B
INSULATION
_
_
INSULATOR
ASS_,C_e_KSHAFTPUU-EY
3. 5535A
1. 3311C
2. 1720B
INTERCOOLE_AS_
3.7001
HAND_
_
ASS_, IN,,ECTOR
HARb_SS (_UND
_
_,
EI.EC'PRO_K;_
INJECTOR
ENGINES_%_S
LR,IT TO
TO DISCOI_NECT
6SPI6"t_B09© I99_DE1'ROIT
DIESELCORPORATION
1-5
ALPHABETICAL INDEX
SERIES 60 PARTS CATALOG
PART NAME
GROUP
ISOLATOR, ROCKER COVER BOLT
NO.
PART NAME
GROUP
1. 8461A
j
O
_ I_E
_f_
OVEF_dAI.A.
t¢C,_
JACOBS BRAKE CYLINDER
1,8070
NO.
_
12.8_
2.2OO4
_
I_, OIL PUMP
4. 1003A
K
p
I_T ENGINE _
1. 1006
PAIN_ ENGINE TOUCH-UP
12,8001A
Ifff FRESH WATER PUMP
3.7180
PAN, OtL
4. 7001A
3. 5004A
PANEL _L
7. 7470B
WASTEGATE AC1UATOR
KE CONNECq'ING ROD BEARING AND GASIET
1,6_6
PANEL INSTRUMiSWf
12.8300A
COOLANT ANALYSIS
12.8290A
PIN, AUGNMENT
2. 2012
COOLANT .LL=VEL
SENSOR
2. 1670B
PIN, _
1. 6140
I_l; C'YUNDER UNER AND SEALS
1. 6181
Pt_ _,
1. 4074A
PIPE, OIL PUMP INLET
4. 151013
2. 15(_.B
PIPE, OIL PUMP OUTLET
4. 15806
FIL3"ERMAINTENANCE-FUEIJOIL
123005A
PISTON Iffl"
1. 6110
_
12.8293A
PLATE ASSY., ELECTRONIC [_'r_BUTOR
ENGINE ADAPTA'RON
KE, EPROM ST_
ANALYSIS
KIT, _,ATOR
_
TENSIONER & BF-L,'-S
__,.JAcosssm,_ FtE_
_....
.....................................................................
_, LOW_ ENC_NE
BF_J_NGS
ANDC_S_S
OIL ANALYSIS
7. 1940A
4. BOOIA
BI_
UNIT
COLD
2. 15_'_R
1.80za ...............
pLA'rE,
Ct_ ,_.ND
,e,_c_c_-.u_r _s-r
PLATE,
FLYWHEB_
_
C(XPUNG
1._03
......
t:-m,'u ..........
_.40_A
12.8291A
PLUG SPARK
i_, C/_..RLLIDRAIN
4. 50_0A
PLUG,BREATHER
HOLE
F3T,P_=OWER CONNECTOR AND TERMINAL
2. 1755B
PLUG, O_LCOOLER B_._S
KE "n.IBING
12.83g0A
PLUG, OIL PAN DRA_
4. 7060A
3. 5008A
POWER TAKEOFF ASSY
8. 100"IA
12.8715C
PROM AND CARRE_ ASSY, EI.EC'_ON_
CONTROL
2. 156513
PULLEY
AND
HUB
ASSY.,
FAN
5._0_
PU_,
ACCESSORY DRIVE
1. 7605_
_
REPAIR
lEO3, S_CMC_ (ALL)
L
7. BT00C
4. 8043A
VALVE
4. 4160A
LAMP,INSTRUMENT PANEL
12.8360A
_
CRANKSHAFT
1. 3280C
LC_ DISPLAYASSEMBLY
7. 7701C
PULLEY,GENERATOR
7.15(}0A
7. 743(:_
PUMP ASSY, FRESHWATER
5, 1001
1. 8370
PUMp ASSY., FUEL
2. 2001
1.7E_0B
PUMP ASS_., HYDRAUUC
12_001A
12_110A
PL_
ASS_., OIL
4. I_A
LEVER CONTROL _AND
THROTrLE
LOCK, EXHAUST VALVESP_NG
_,
ACCESSORY DP_VE
_'[_IG
COMPOUND THREAD
M
R
I_,I_
6.10EIA
IE-CO_NG
MINDER, ENGINE/MAS'f_R
2. 189(_
REGULATOR ASSXNAT GAS
2. 4136A
2. 4137A
F_GULATOR, OIL PRESSURE
4. 1670C
2. 1501B
P_,
VALVE OIL PP_SSUP_
4. 1671C
MODULE SPAP_ _ACE
7. 8725C
I_EPAIR KEf,C(}NNECTOR AND SEAL _
2. 1758B
MODULE, BOAT BUILDER IN'T_RFACE
2- 151213
REPAIR _
2. 1 ."_,"u
MODULE, CONI_OL STATION IN IP-HFACE
7. 7_
P_'TAINE_ BREA'i'HI_ pAD
4. 8065A
MODULE, ELECTRONIC,DtSTRIBUTOR UNE _._
2. 151(_,
FETAINER, CAMSHAFT AND ACCESSORY GFJ_
1.7240
MODULE, ENGINE ROOM INTE_=tFACE
7. 7440B
RET_
CLUTCH PILOT BEARING
1. 4045A
MODULE, S_INAL NOISE ENHANCEMENT
MOTOR ASSY., STARTING
2. 1655B
7. 3001A
RETAINER, FRESH WAFER PUMP BEARING AND
SEAL
5. 1071
MOUN_NG,
11.1072A
RETAINER, PISTON PIN
1. 6150
MI_ING UNiT
MODULE ASS_, B..EC'r_oNIC _OL
]-6
ENGINE FRONT S_
(ECM)
ELASTIC
_, FRESH WATER PL_4P
HARNESS TERMINAL
5.I(3_
Aqlnfcw_Jonsub_ctto chang_wN'_out
no_e. AIIr_msreserve:L
_l:Vl_l _
© 1998 DE"i'ROlI D[ESE.LCORPORATION
SERIES 60 PARTS CATALOG
PART NAME
ALPHABETICAL
GROUP NO.
PART NAME
GROUP NO.
RING SET,PISTON
1.6115
SHIELDING, FLEXIBLEHOSE
2. 5255A
RING, INJECTORSEAL
2. 1040A
SHIM, OIL PUMP
4. 10_0A
RING, PISTON COMPRESSION
1. 6120
SLEEVE,CRANKSHAFTOIL SEAL
1.3167A
RING,PISTONOILCONTROL
1.6130
SLEEVE,CRANKSHAFT
REAROIL SEAL
1.3066
ROD, PUSH
1.8180
SOCKE'_,LAMP INSTRUMENT pANEL
1IL_I65A
ROTATOR,VALVE
1. 8365
SPACER,GENERATOR ADJUSTINGS/RAP
7.1581A
S
SPACER,IDLER GEAR BEARING
1.7"226
SPACER,PULLEY
5. 4018A
1. 8173
SCREW, ROCKERARMADJUSTING
1. 8135
SPACB_,ROCKER SHAFT
SEAL,ACCESSORYDRIVEOIL
1. 7660B
SPACER,VIBRATIONDAMPER
1.32758
SEAL, BALANCEWEIGHTCOVEROIL
1. 7472A
SPINDLEASSY.,FAN DRME
5. 4102A
SEAL,CAMSHAFTTHRUSTPLATE
1. 7075
SPINDLE,CRANKSHAFTPULLEY
1. 3283C
SEAL CRANKSHAFTOIL
1. 5004A
SPRING, EXHAUSTVALVE
1. 8340
SEAL CRANKSHAFTOILFRONT
1. 3166A
SPRING, OIL COOLER BYPASSVALVE
4. 4150A
SEAL,CRANKSHAFTOIL-FRONT
1.3040
SPRING, OIL RLTER BYPASSVALVE
4. 2486A
SEAL,CRANKSHAFTOIL-REAR
1. 3060
SPRING, OIL PRESSURE REGULATOR
4. I(EOC
SEAL,C'f'L.tNDER
LINER
1.6190
STAND,ENGINE SHIPPING
11,1045A
SEAL,FAN SPINDLE
5. 4160A
STRAINERASSY.,SPIN-ON FUEL
2. 3006A
SEAL,FRESH WATERPUMP
3. 7210
_
12.430(_
SEAL,FUEL PUMP OIL
2. 2070
STRNNER,OILRLLERTUBE
SEAL.THERMOSTAT
5. 2060B
_
SEALANt, RI"V
12.8255A
SI"Ft/_,_aPE ASS_ TO _TOR
SEAT'EXHAUSTVALVESPRING
1.8360
STI._, B0-tAUSTMNdlFOI_ "1"O
_
6. 1022A
SEAT,OIL PRESSUREREGULATOR
4. 1701C
SUPPORTASS_, FANBELTIDLER PULLEY
5.4347A
SENSOR ASSY.,KNOCK
2. 1648B
SUPPORT,BELTTENSIONER BRACKET
7. 1935A
SENSOR, AIR INTAKE
3. 3810C
SUPPORt, ENGINE FRONT
11.1070A
SENSOR, AIR PRESSURE
2. 165OB
SUPPORT,ENGINE REAR
11.1100A
SENSOR, AIR TEMPERATURE
2. 1647B
SUPPOR'_,FANMOUNTING
5. 40_5A
SENSOR, COOLANTLEVEL
2. 1665B
SUPPORT,GENERATOR BRACK_'T
7. 1596A
SENSOR, MAGi.CRANKSHAFT
2. 1620B
SUPPORI_OIL FILl ._r(MOUNTING.
4. 2470A
SENSOR, MAG. IDLER
2. 16106
SWITCH, EMERGENCY BACKUP
7. 7465B
SENSOR, OIL OR FUELPRESSURE
2. 160OB
AIR _
ON _
4. 5Q_0A
GENERATOR
_
s scR.OLFUEL
ORSo0.n"TIw'6 TI., 2.,mn
7. 1580A
_
7. 1633A
T
SENSOR, OXYGEN
2. 1671B
TENSIONERASSY.,GENERATOR ORNE
7. 1900A
SEPARATOR,FUEL'_ATER
2. 3590A
TENSIONER, BELT
5. 4340A
SERVICE KIT,INJECTOR
2. 1Q(]P-.A
TERMINALRING TYPE
1. 8810
SETS, SERVICE(ALL)
SHAFT AND GEARASSY.,OILPUMP DRIVE
12.8720(3
4. 1065A
THE_%MOSTAT
ASSY.
THERMOSTAT,LUBE OIL
5. 2050B
4.
SHAFT AND GEARASSY, OILPUMP DRNEN
4. 1075A
THREADLOCK& SEALB:t
12.S24P.A
SHAFTASSY.,FRESHWA'l.¢:H
PUMP
5.1050
TRIPRECORDERANALYSISCONTROL SYSTEM
2.190013
SHAFTASSY.,ROCKER
1. 8160
TUBE AIRINTAKI=
2. 4171A
SHAFT,ACCESSORYDRIVE
SHAFT,AIR COMPRESSORDRIVE
1. 7640B
12AO47A
TUBE EXTENSION (NATURALGAS ENGINE)
TUBE GASGOVERNOR INLET
1. 8453A
2. 4170A
SHAFT,TACHOMETERDRIVE
7. 4435B
TUBE, AIR COMPRESSOR BOOSTER
12.4375A
SHELL,BREATHER
4. 8(T=SA
TUBE, AIR COMPRESSOR LUBE OIL DRAIN
12.4070A
SHELL, CONNECTINGRODBEARING
1.6100
TUBE, AIRCOMPRESSOR LUBE OIL SUPPLY
12.4065A
SHELL,CRANKSHAFTMAIN BEARING
1. 3080
TUBE, AIRCOMPRESSOR WATERINLET
12.4085A
TUBE, AIRCOMPRESSOR WATEROUTLET
12._
TUBE, FUEL PUMP TO CYLINDER HEAD
2. 5101A
SH]l=:/nASSY.,ELECTRONICUNiT DISTRIBUTOR
HEAT
_Sl
INDEX
UOO © lg,_sDEmorr DIESF.L
COePOR_ON
2. 1525B
1--7
ALPHABETICAL INDEX
PARTNAME
SERIES 60 PARTS CATALOG
GROUPNO.
TUBE,GENERATOR
OiLDRAtN
7._O0SA
llJSE, GENERATOROIL SUPPLY
7. 1004A
TUBE, INTAKEADAPTOR
2. 9397#.
TUBE,JUNCTION BLOCKTO COLD PLATE
2. 5167A
TUBE,JUNCTION BLOCKTO CYLINDER HEAD
2. 5175A
TUBE, OiL FILTER
4. 5001A
TUBE, OiL FILTERINLET
4. 300tA
TUBE, OiL FILTEROUTLET
4. 3020A
TUBE, STRAINERTO FUEL PUMP
2.-5050A
TUBE,TURBOCHARGEROIL RETURN
3. 5505A
TUBE,TURBOCHARGEROIL SUPPLY
3. 5500A
TUBE, WATERBYPASS
5. 2160C
TUBE, WATERPUMP TO OIL COOLER
TURBOCHARGER
5. 3400B
3. 5001A
PARTNAME
GROUPNO.
V
VALVEASSY.,FUEL PUMP
2. 2130
VALVE, EXHAUST
1. 8310
VALVE, FUEL DRAINCHECK
2, 5209A
VALVE,FUEL SUPPLYCHECK
VALVE,FUEL SYSTEMSHUTOFF
2. 5006A
2_5260A
VALVE,iNTAKE
1. 8315
VALVE,OIL CONTROL(THERMATIC)
VALVE,OIL COOLERBYPASS
4. 4066A
4. 4140A
VALVE,OiL FILTERBYPASS
4. 2485A
VALVE,OIL PRESSUREREGULATOR
4. 1700C
W
WASHER,CBANKSFL_FT
MAIN BF-A_NGTHRUST
WiRE SPARKPLUG
1- 8
1.3100
7. 8715C
A/li_'_waldon
sN_isctlocr_ngewltllout
notice.AIInghts_.
sSPt 61 _
© t998DETROIT
DIESELCORPORATION
DETROIT
DIESEL
SERIES 60 ENGINE
AIR INTAKE
MANIFOLD
DRIVE
(7.4420)
DRIVE
(1.7600)
PUMP
(2.2001)
--
-FAN
DRIVE
SPINDLE
ASSEMBLY
(5.4102)
--
VIBRATION DAMPER
(1.3210) _
AIR COMPRESSORDRIVE
(12.4030)
FUEL FILTER
(PRIMARY)
(2.3320)
STARTING
MOTOR
(7.3001)
FUEL FILTER
(SECONDARY)
(2.3010)
I=1FCTRONIC
CON I NOL
MODULE
(2.1501)
--
AIR COMPRESSOR
(12.4001)
TYPICAL SERIES 60 ENGINE
SHEET1 OF 2
© 1993 Dr=I HOlT DIESEL CORPORATION
DETROIT
DIESEL
SERIES 60 ENGINF
TURBOCHARGER
(3.5001 --
(6.1001)
ROCKER COVER -(1.8450)
--
(5.2050)
FLYWHEEL
HOUSING
(!,500!)
f
WATER PUMP
(5.1001)
BYPASS
OIL FILTER
(4._5o)
-FLEX PLATE
(1.4085) --
OIL COOLER
(4.4001) --
--
OIL PAN
(4.7001)
OIL FILTERS
(4.2250)
TYPICAL SERIES 60 ENGINE
SHEET2 OF 2
© 1993 DETROIT DIESEL CORPORATION
DETROIT
DZESEL
CUSTOM PARTS CATALOG 03/21/OO
O6R0534878
PART #
1.2000
N_J4E PJ_D DESCRIPTION
- CYLINDER
1.2045
TUBE,
23501530
1.2046
RING,
23515470
8929123
8329328
R23525566
EFFECTIVE
b/ITH
HEAD
INJECTOR
HOLE
TUBE KIT
(INCLUDES
SEAL RING
IN 1.2046)
INOECTOR
HOLE TUBE SEAL
SEAL RTNG INO TUBE GREEN FLUOROCARBON
BOLT,
N16 X 2 X 175 (12.6005)
WASHER,
16.B"
X 25.8"
(12.9190)
*
HEAD ASSY.,
3 BOLT THRUST PLATE N/RACE
TP.ACK
UNITS
6R37024
WITH 23506350
EXHAUST
VALVES.
1.2002
GASKET KIT,
GASKET KIT CONSISTS
23501572
1.2010
GASKET,
23522588
1.2000A
......
-
CYLINDER
HEAD OVERHAUL
OF ALL GASKETS NECESSARY
GASKET KIT
CYLTNDER
HEAD
GASKET,
ENGINE,
LIFTER
ENGINE
1.2080
BRACKET,
8929408
23518652
11509528
ENGINE
1.3003
KZT,
23528280
23519904
23519505
1.3040
SEAL,
NOTE
LIFTER
- REAR
BRACKET (ZTEN
2)
BRACKET ENG LFTR
BOLT.
N12 X 1.75
-_
1
1
2
NN
RR LB HI) pLATED
X 30 NM
_TABTL_I"ZERS
1
1
S
SBO
.......................................................................
(NON-ARTZCULATED
STEEL PZSTON)
LOWER ENGINE
BEARING
AI_
GASKET
(NON-ARTZCULATED
STEEL pISTON)
LONER ENGINE
BEARING
AND GASKET
CP.AM_SHAFT
USE
1
AR
AR
.OIOUS
AR
.02BUS
AR
47144
AR
AR
_FT
(REFER
TO
1.3168
ZN 1.3000A)
TO
1.5OO4
IN
OIL-REAR
AR
SEAL
1.3066
SLEEVE,
NOTE
47MR
RUST BE
0ZL-FRONT
SEAL
1.3060
SEAL,
NOTE
HEAD.
AR
LOWER ENGINE
BEARINGS
AND GASKETS
KIT,
LDt/ER END BRG 47NN & GASKET
(NARZNE ARTICULATED
STEEL PISTON)
LOWER ENGINE BEARING
AND GASKET 47NN
(NON-ARTZCULATED
STEEL PZSTON)
LIDI_E[R ENGINE BEARENG A_D GASKET 47RH
23524260
SEAL
ONE CYLINDER
ASSY.
FOR WIDER COM_ ROD BEARINGS
AM) CONN ROD ASSYS.
TO ENSURE ZNTERCHANGEABZLZTY.
CRANKSHAFT,
6 HOLE 12.7L
(ACCOMI40DATE
_ZDER COtE_ ROD BEARINGS)
23519506
6
38
38
AR
CONPRESSZON
CYLTNDER
HEAD
LTFTER-FRONT
BRACKET (ZTER
1)
BOLT, N14 X 2.0
X 40
_ -_-_;_--OEL-_SEA_S
1.3001
_T
NEW _FTS
D TOGETHER
23515598
TO REPLACE
5
BRACKET
1.2070
BRACKET,
8923754
11509530
1.3000
_J_N_ITY
CRANKSHAFT
(REFER
REAR
OIL
1.5OOOA)
SEAL
AR
SLEEVE
(REFER
TO
1.5012
ZN
1.50OOA)
1.3090
SHELL,
CRANKSHAFT
NAZN BEARING
A SHELL SET CONSTSTS OF ONE UPPER AND ONE LOWER BEARING
SHELL.
...SOME
UNITS
NAY REQUIRE
A LDWER MAIN THRUST KIT.
REFER TO YOUR CYLTHOER
LOCK TYPE ZN 1. 1035
TF REQUTRED.
8929870
SHELL SET,
STA_E)AI_D (MAIN)
8928671
SHELL SET,
.254m4
UM)ER SIZE
(MAIN)
8929672
SHELL SET,
.508NN
UNDER SIZE
(14AZN)
8929673
SHELL SET,
.762NN
UNDER SIZE
(MAIN)
8929880
SHELL SET,
ST/b_)ARD
(_ST)
8929881
SHELL SET,
.254m4
UNDERSIZE
(THRUST)
8929582
SHELL SET,
.508NN
UNDERSIZE
(I"FERUST)
2
B
6
AR
AR
AR
1
AR
AR
DETR0
ZT
DZ ESE
L
CUSTOM PARTS CATALOG 03/21/00
06R0534878
pART #
NANE AND DESCRZPTZON
1.3OOO
- CRA_HAFT,
8929683
OTL SEALS _
SHELL SET,
QUANTZTY
STABILIZERS
.762NN UNDERSZZE (THRUST)
AR
1.3100
WASHER, CRANKSHAFT NAZN BEARING THRUST
9929085
WASHER, (UPPER THRUST ONLY)
8929697
WASHER, . 127NN O. S8929698
WASHER, .254MM 0.S.
2
AR
AR
1.3110
CAP. CR_NNKSHAFTNAZN BEARTNG
8929276
CAP, NATN BEARTNG (UNSLOTTED)
7
1.3140
BOLT,
8929124
8529125
14
14
CRA_
MAIN BEARING CAP
BOLT,1420
X 178.0
WASHER, SPECZ_L
1.3145
GEAR, CRANKSHAFT TINING
23513537
t_EL,TIMING
RING (2.314B)
8929487
GEAR, RH, 8ST, 133.8NN I.D.
8929808
KEy,
.25"X1.375
R (12.9350)
1.30OOA
- CRAI_
1
1
1
12.7L
FRONT COVER
1.3156
HOUSZNG ASSY., GEAR CASE
23505875
HOUSZNG ASSY. , REAR NOUNT WATER PtJNP
(TNCLUDE5 89293,33 BOLTS & DOWEL PINS IN 1.3156)
8929760
SUPPORT
(1.3160)
8929015
DOWEL pTN, 16 NG. , CIRCULAR ( 1 . 1001 )
8929022
DOWEL PIN 16 NG. , DTANOND ( 1 . 1001 )
8929740
SEAL, RING . 134X.074X.480 Z.D.
)
23505062
11503454
11505299
11513811
181333
8929333
5155596
5180370
BOLT, MIO X 1.5 X 40
BOLT, MlO X 1.5 X 20.0
BOLT, NlO X 1.5 X 30.0 NN
BOLT, M12 X 1.75 X 20 NN
BOLT, 6/16"-24
X .625"
BOLT, M12 X 1.75 X 65 (SPECIAL)
WASHER, 21/64"
SPECIAL COPPER (4.7120)
WASHER, .56"
LD.
COPPER (7.4969)
1
1
1
1
1
9
2
4
1
1
3
1
1
1.3158
COVER, r_rAR CASE
23505875
COVER, FR_
11504986
BOLT, 148 X 1.25 X 14 1414
5141452
SEAL, RING (3.4143)
8924517
PLUG, 3/8"-18
SQ. SOC. VZBRA SEAL (12.9550)
11509523
BOLT, 1410 X 1.5 X 55 NN
1150Q626
BOLT, MlO X 1.5 X 110 NN
23507422
GUARD, BOLT V18 DNPR & FRT CVR
1
2
1
1
14
4
1
1.3166
SEAL.
23518356
1
CRA_
OIL FRONT
SEAL FRONT (:R/SHAFT
CR UNZTTZED 5ARPAROUND
1.3191
COVER,
23517382
8929069
11504822
EI_N_
1.3192
GASKET,
8929299
9929130
ENGINE FRONT ACCESSORY DRIVE
GASKET,
ACCESSORY
FRONT
GA._,
UPPER RZGHT REAR & FRONT C_
1.3000B
FR0_T ACCESSORY DRIVE
COVER. ACSRY REAR 6 HOLE
COVER, FRONT ACCESSORy
BOLT, 148 X 1.25 X 30
1
2
11
ACCESS.
2
1
- VZBRATZON D_J4PER
1.3210
DAI_ER,
8929502
VZBRATZON
DANPER, 11L & 12.7L
1.3279
SPACER, VZBRATZON DPJ4PER
8929527
:_
SPACER
5133981
WASHER, 19/32"
(1.1001)
8929222
BOLT, 9/16"-18
X 2 1/2"
s USE SPACER _HEN CRANKSHAFT PULLEY 1"5 NOT RE(_JTREO.
3
1
1
5
6
D ET ROZT
D1ESE
L
CUSTON PARTS CATALOG 03/21/00
06N_:34878
PART #
1. 3000C
-
NANE AND DeSCRZPTTON
CRANKSHAFT PULLEY
1.3280
PULLEY,
8529077
8829222
5133381
1.4000A
-
qUANTZTY
CRANKSHAFT
PULLEY. 188.0NN O.D..
4 GROOVE (ZTEM 3)
BOLT. 9/18"-18
X 2 1/2"
WASHER, 19/32"
(1. 1001)
1
6
6
FLY--EL
1.4001
FLY--EL
ASSY.
INCLUDES GEAR ZN 1.4010.
"C" ZNDICATEB A CHAMFEREDASSY.
23514751
FLY--EL
ASSY,SAE1 TYPE 1,GI4-10 & 1.76
5100532
PLATE, SCUFF (BEARZNG RETA;NER)
9410925
BOLT, 9/16"-18
X 2 1/4" (12,9001)
1
1
12
1.4010
GEAR, FLYM'I_L
RZNG
5154773
DEAR, SAF. #1,
1
1.5000A
-
FLYk_EL
11B TEETH, UI_ERED
ltOUSING
1.5001
HOUSZNG ASSY., FLY--EL
23522539
HOUSZNG ASSY FLYtiH[EL SAE #1
1.5001
HOUSTNG ASSY., FLYWHEEL
23511574
PLUG, 1" PZPE SQ. SOC. SCOTCHGRI"p
23514442
pTpE PLUG 1 1/4 7/8 TPR SQ SOCHD
5106589
PLUG, 3/4"-16
23522327
BOLT M14 2.00 X 50.0 LG Hex HD
23522325
BOLT M14 2;00 X 95.0 LG HE)( kID.......
1
1
1
1
8
4
............. _522_s ........................
_
..................................................................................
12
s[_, cn_s_uu_r OZL
23515551
SEAL,NEAR
C_/SHF
1
1.8000 - cmemcrzm_ ANDPZST-m
1.SOOl ce_._crzm RODkssv.
QUANTZTIE5 SHOWN ARE PEn CYLZNDER. A CROS_D
ROD ASSY. ZNCLUDE5 A CAP. M-I
ZCH XS NOT SOLD SEPARATELY, AND WILY THOSE x'rlms ZN 1 .6001 .
N_ CR_S
FOR t_DER _
ROD BEARINGS ANO _
ROD ASSYS. MUST Be USE
D TOGETHER TO e_
ZNTeRCHAI_r.ABILITY.
23515533
ROD ASSY., 15:1 12.7L (SIDER BEARTNG SURFACe)
1
8929355
BOLT, IkJ14 X 1.5 X 108
2
8929019
NUT,Md14X1.5
2
1.6095
KZT,
23521522
CO_CTZNG
ROD BEARING AND GASKET
KIT C_
ROD BRG (STD) AND GASKETS $60 4784
(W/WTDER _
ROD BEAR;'NG$)
AR
1.6100
SHELL, CONNECTTNG ROD BEARING
A SHELL SET CONSZSTS OF ONE (1) UPPER AND ONE (1) LOWER BEARZNG SHELL.
NEW CRANKSHAFTS FOR WZDeR CO_ RO0 BEARZNGS AMD CONN ROD ASSYS. NUST BE USE
D TI_ER
TO ENSURE ZNTER_ZLZTY.
23515581
SHELL SET, S'rD. (WZDER 8EARZNGS)
1
23515582
SHELL SET, .254 la U.S. (WIDER BEARINGS)
AR
23515583
SHELL 5LL-I
", .508 114 U.S. (_IDER 5EARZNBS)
AR
23515584
SHELL SET, .752 I_1 U.S. (WIDER BEAI_NGS)
AR
1,6110
PZSTON KIT
A P$STON KZT ZNCLU13E5 PZSTON ASSY, , 3 PC. EUSHZNG, SKIRT _
PXW _rW 1.6140.
QUANTZTZES SHOWN ARE PER CYLZROER.
23519545
PZS_
KIT, LRG 00 DOME & SKZRT 2.51m# RG
1
1,5115
RZNG SET, PZSTON
RZNG SET CONSISTS OF SUFFZCZeNT RINGS FOR ONE (1) PZSTON.
23503747
RZNG BET, W/KEYSTONE COMPRESSZONRINGS (2.,_101 TOP)
1
1.8120
RING,
8929844
8929845
1
1
PISTON COMPRESSIOR
RZNG, TOP (2.5 im KEYSTI_)
RTNG, BOTTOR (KEYSTONE)
__ .......
nETRO
ZT
DT ESEL
CUSTOM PARTS CATALOG 03/21/00
06R0534878
PART #
1.6000
-
NANE AND DESCRZPTZON
QUANTTTY
CONNECTZNG RO0 AND pTSTON
1.6190
RZNG, PZSTON OZL CONTROL
23515500
RZNG PSTN OZL CON1"CR/HD
23515499
EXPANOER
1
1
1.6140
pTN,
8929087
8929337
8929504
1
2
2
PZSTON
pTN
BOLT, R14 X 1.5
SPACER
1.6142
BEARZNG, PTSTON PZN.
KZT TNCLUDES (1) TOP BEARZNG AND (2)
PARATELY.
23519723
KZT BEAR][NG
X 60
12 PT.
EAR BEARZNGS VHZCH ARE NOT SERVZCED SE
1
1.6181
KZT, CYLZM)ER LTNER AM) SEALS
KZT ZNCLIJOES NOT 5ERVlrCED SEPARATELY LZNER AND SEALS ZN 1.8190
23523948
KZT, LZNER TOP COOLTNG & SEALS
1
1.6182
CYLZNDER KZT
A KZT ZNCLUDES ZTEI4S ZN 1.Gl10,
1.8115,
1.6140 AND 1.6181.
R23523954
KZT, CYL ELLZpTTCAL DONE 2.5m4 RG PRESS FZT BRG
1
1.8130
SEAL,
8929013
1
1. 7000
-
CYLZNDER LZNER
SEAL,
CREVZCE
CANSHAFT AND GEAR TRAZN
1.7001
_
ASSY.
A CJU4SHAFT ASSY. ZNCLUDES DOWEL ZN 1.7001.
23524906
CAMSHAFT ASSY., 12L
8920172
DOWEL, C4849HAFT ( 1,7200)
1
1
1. 7037
CO.R.
23514716
11509511
1
3
CAMSHAFT BEARZNG CAP
COVER RE _
BOLT, 148 X 1.25
S60
X 20 N4
1.7040
5EARZNG, CANSHAFT
A BEARZNG SET CONSZSTS OF ONE UPPER AND ONE LOWER BEARZNG SH_LL.
8929690
BEARZNG SET (STD.)
8929691
BEARZNG SET, .254 II O.S.
8929892
BEARZNG SET, .508 NN O.S.
8929693
BEARZNG SET, .762 IOI O.S.
1. 7042
CAP, CAMSHAFT BEARZNG
23522645
CAP, #1 CAI4SHAFT BEARZNG FRT RACE TRACK SEAL
(USED WTTH 23522375 RACE TRACX SEAL)
8929870
CAP, CANSHAFT 8EAR][NG. ZNTERNEDZATE (1.7042)
8929871
CAP, CANSHAFT BEAR][NG, CENTER (ZDENTTFZCATZON-NO.)
8929739
CAP, C4USHAFT BEARING, REAR (ZDENTZFICATTON-NO.
7)
8929740
SEAL, RTNG .134X.O74X.480
I.D.
5138638
*
DOWEL, .825=X.37 m HOLLOW (4. 1040)
= FZG. 1 OF 1.2000.
1.7046
BOLT, CANSHAFT 8EARZNG CAP
8929129
BOLT, N12 X 1.75
X 85
CAM _
BALANCE SHAFT THRUST
PLATE, CAM THRUST 9 BOLT
BOLT, 148 X 1.25 X 30
1.7075
SEAL,
23521894
8923318
CANSHAFT THRUST PLATE
SEAL, C.M4 THRUST pLATE TO CYL kID 3 BOLT
SEAL (GEAR HOuslrNG)
5
1
4
1
1
1
7
7
t .7070
PLATE,
23521892
11504822
1.7200
GEAR, CANSHAFT AM) BALANCE SHAFT
23521895
GEAR ASBY. ,CANSHFT DRTVE 3-8LT
8929379
GEAR 111T
7
AR
AR
AR
1
3
TRSTPLT NTTR
1
1
1
1
DETROZT
D Z ESE
L
CUSTOI_ PARTS CATALOG 03121100
06R0534878
PART #
1. 7000
_
....
QUANTZTy
- CAMSHAFT AND GEAR TRAZN
1. 7206
HUB, CAMSHAFT GEAR
8329810
KEY, NON ROCK (12.9350)
23524883
HUB CAM DRV GEAR
23524882
BOLT, M20 X 1.50 X 100.0
1
1
1
1.7220
GEAR ASSY. , ZDLER
A GEAR AND HUB ASSY. ZS SERVZCED AS A COMPLETE ASSY. ONLY.
P.23513559
GEAR ASSY. ,CAMSHF/ACSRY SRG & HUB
8929448
BOLT, Mt2 X 1.75 X 35
1
4
1,7221
GEAR ASSY. , ADOUSTABLE CAMSHAFT ZDLER
8929322
GEAR ASSY- (ZNCLUDES BUSHZNG t_IZCH 1'5 NOT SERVZCED
SEPARATELY )
1
1.7255
HU_,
8929111
11509607
8929336
1
3
1
1 .?O00B
.
NAME AI_) DESCRZPTZON
AD,JUSTARLE ZDLER GEAR
HUB
NUT, N12 X 1.75
PLATE,ADOUSTMENT
-ACCESSDR¥
ORZVE
1.7800
DRZVE ASSY., ACCESSORy
23509200
DRZVE ASSY., 2 GROOVE 120.0 Ira4 PULLEY LR5 5RG
1. 7605
PULLEY, ACCESSORY DRZVE
11509584
NUT, LOCK il24 X 3.0
8929532
.....
PULLEY; 2 GROOVE 120. OYM
ii ......................
1_J622__
,- -ACr_,ESSeW_ORZ_E....................................................
23509201
HOUSZSIS
_.......
1. 7540
SHAFT, ACCESSORY DRZVE
2350S202
SHAFT,
LRG
5RG
1.7r_,2
GEAR, ACCESSORY DRZVE SHAFT
8929310
GEAR
1. 7550
LOCKRZNG, ACCESSORY DRZVE
23509204
LOCKRZNG
K525062
LOCKRI"NC_
t. 7655
5EARZNG. ACCESSORY DRZVE
23509203
BEARZNG, BALL SGL.
8929024
BEARZNG ASSY.
1.7860
SEAL, ACCESSORY DRZVE OZL
8529154
SEAL
8929253
SEAL, RZNG . 139" X 4.509"
Z.D.
(2.2280)
11504822
BOLT, lU; X 1.25 X 30
1 .8000
- VALVE AI_
1
1 .....
.1 ....
1
1
1
1
1
t
1
1
1
5
ZNJECTOR OPERATZNG MECHNeZSM
1.8050
HARNESS ASSY.,
ZNUECTOR
23513805
HARNESS EDU TO ZNJ
USES 12034222 TERMZNALS
1
1.8060
ARM ASSY., EXHAUST VALVE ROCKER
ARM ASSY. ZNCLUDES 5USHZNGS, PZNS AND ROLLER ASSY. COMPONENTS NOT SERVZCED
SEPARATELY.
23523174
(R) ARM & RLR ASSY. EXH RKR _/00ZL
HOLE
9421740
PLUG, CUP 3/18 _ (i2.5320)
6
12
1. 8075
ARM ASSY., ZNTAKE VALVE RO(]_R
ARM ASSY. ZNCLUDES _.tSHZNGS, PINS AND ROLLER ASSY, COMPONENTS NOT SERV;CED
SEPARATELY.
23520644
(R) ARM & RLR ASSY. lINT RKR _//0 OZL HOLE
B
1. 8080
ARM ASSY., ZNdECTDR ROCKER
ARM ASSY. SNCLUDES 6USHZNGS, PINS AND ROLLER ASSY. COMPONENTs NOT SERVXCED
SEPARATELY.
R23513939
REMAINUFACTURED23513339
23513939
ARM ASSY., ZNd RKR CER RLR HONED BU5HZNG
AR
8
1.8135
5CRFM, ROCKER ARM A[_JUSTZNS
23505OS6
KZT, VLV. ADd SCREW IrNd & ZNTAKE ARMS
AR
5
DETROIT
DT ESEL
CUSTOtl PARTS CATALOG 03121/00
06R0534878
PART #
1.8000
NAME AND DESCRZPTZON
Q_U_N_I"TTY
- VALVE AND :N4ECTOR OPERATING NECI'_,_ZS_4
8323846
KZT, VLV ADU. SCREW EXH ARNS
23517283
BUTTON, VALVE $50/60
23520013
SCREW ASSY. , ZNT VLV ADU M/O OTL HOLES
23520014
SCREM ASSY. , EXH VLV ADU M/O OZL HOLES
8329807
SCREM, M/3/16"
XNTERNAL SOCKET END
23514371
MJT, 3/8"-24
HEX UAN
8929494
RETAZNER ( 1.8090)
AR
30
6
is
IS
30
30
1.8180
SHAFT ASSY.,
23513530
23521734
23521
t11
235229?5
8929588
8929740
9421745
23500708
892958?
2
2
2
1
2
1
2
2
8
ROCKER
SHAFT ASSY. , LUBRZTED (ZNC1.UDE$ PLUG)
STUD/SEAL ASSY.
SEAL
SEAL, RACETRACK FRT CAMSHAFT CAP
STUD, M12 X 1.75 X 123.0
(1.8170)
SEAL, RTNG . 134X.O?4X.480
Z.D.
PLUG, CUP 1/2"
(12o9330)
NUT, M12 X 1.75
BOLT, M12 X 1.75 X 110.0 (1.7046)
1.81"/3
SPACER, ROCKER SHAFT
8929586
SPACER (01,8170)
8
1.8310
VALVE.
23507504
EXHAUST
VALVE KZT (ZOENTZFZCATZON-H)
(ZNCLUDES SEAL I'N 1.8320 AND LOCK XN 1.8370)
12
1.8315
VALVE,
23501578
ZNTAKE
VALVE KZT (TNCLUDES SEAL I'N 1.8320
370 )
N_B) LOCK ZN 1.8
12
1.8320
CUZDE, EXHAUST VALVE
23518571
GUTDE
235185"/2
CUZDE VALVI.:
23523930
SEAL F_ VALVE S'I'EN (4 VLV)
24
AR
24
1 . 8330
I"NSERT, F._tAUST VALVE
8329127
ZNSERT,
8329625
I"NSERT,
8929626
ZNSERT,
8929637
ZNSERT,
8929126
ZNSERT,
8929628
ZNSERT,
8929629
ZNSERT,
8929630
ZNSERT,
12
AR
AR
AR
12
AR
AR
AR
(TNT/_KE) (STD) (7.155_8-7.25?1i)
(ZNTAKE) (.010"
U.S.)
(6.901NN-T.OO3MM)
(ZNT_KE)
(,020"
U.S.)
(6.6471194-is.7491M4)
(ZNTN(E)
(.030"
U.S.)
(6.393NN-IS.495NN)
(E,X]HAUST) (STD) (8.261NN-6.36318)
(E)_"IAUST) (.010"
U.S. ) (6.00718#-8. 1_)
(EXHAUST) (.020"
U.S. ) (5.7531i-5.855NM)
(EXHAUST) ( .030 U.S. ) (5.4991m-5,601m4)
1 .8340
SPRZNG, EXHAUST VALVE
8929415
SPRZNG (YELLOM STP.XPE)
24
1 .8330
SEAT,
892907is
8929634
8929635
8929636
24
AR
AR
AR
EXHAUST VALVE SPRXNG
SEAT (2.2J/M-2.4101)
SEAT ( 2.451E4-2. B511)
SEAT (2.70m4-2.90NN)
SEAT (2.95N4-3.15N4)
1.8365
ROTATOR, VALVE
8929105
ROTATOR
24
t .8370
LOCK,
89295"/3
48
1.8000A
E_G'iAUSTVALVE SPRTNG
LI_,
KEY EXHAUST VALVE SPRZNG
- ROCKER COVER
1. 8450
COVER ASST.,
23522272
ROCKER
COVER ASSY. , ROCKER IOBLT SNC VZNYL
1 .8455
GASKET, ROCKERCOVER
23522259
GASKET, ROCKER COVER NOD SEAL
1. 8460
BOLT, ROCKER COVER
7
1
1
DETROIT
DIESEL
CUSTON PARTS CATALOG 03/21/00
06R0534878
PART #
2. IO00A
N_E
AND DESCRIPTION
QUANTITY
- FUEL It_JE_'TOR
2. 1001
INJECTOR ASSY .
R5235895
Z_kJECTOR, (10UM,9.840
2. 1002
SERVICE KIT,
5234934
5236115
X 155)
12L
8
ZN_JECTOR
KIT, EUI GROOVED
SOLENOID
STATOR
KIT,
EUI SOLENOID SEALS & SCREWS
AR
AR
2. 1040
RING, INJECTOR SEAL
FO_NER STYLE EUI II_CTOR
BODY USED 2-UPPER AND 2-1.O_ER SEAL RINGS.
STYLE EUZ INJECTOR BODY USE 1-UPPER AND 2-LO_R
SEAL RINGS.
5234702
RING, SEAL UPPER
5234899
RING, SEAL LOWER
2. 1270
CLANP,
8929088
8929021
8929393
2. 100013
INJECTOR
CLANP
WASHER
BOLT, NlO X 1.5
X 70.0
CURRENT
1
2
8
6
5
(12.9001)
- ZNdECTOR CONTROLS ELECTRONIC
2.1501
NODULE ASSY.,
R23519308
23514772
23512309
23512307
ELECTRONIC CONTROL (ECN)
NOOULE ELECT CONT NOD 12/24V 8 IN
LABEL _OC ELECTI_ONZC CONT
BOLT 148 1.25 SHOULDER 12 PT HD
ISOLATOR, EON _
2. 1520
PLATE ASSY.,
23515935
11504603
ELECTRONIC DISTRIBUTOR UNIT COLD
PLATE ASN COLD ECR END NT DDEC ZT1[
SCREW, NSXI.00X25.0
Ill
2. 1600
SENSOR, OIL OR FUEL PRESSURE
23511178
SENSOR, OIL/FUEL
DOECZV
PRESSURE
2.1810
SENSOR. NAG. IDLER
8929387
SENSOR (SRS)
(INCLUDES 1-8928652
SEAL RING)
11504985
BOLT, 148 X 1.25 X 14 NN
2.1620
SENSOR, NAG. CRA_
8929388
SE_
(TRE)
(INCLUDES 2-8928652
SEAL RINGS)
11504988
BOLT, N8 X 1.25 X 14 NN
2. 1830
SENSOR, OIL,
23518092
23515251
FUEL OR COOL_
SENSOR ASSY.
SENSOR ASSY.
1
1
4
8
1
9
1
1
1
1
1
TENPERATURE
OIL WATER FUEL & AIR TENPERATURE
COOL TENP 3/4 IN. BRS
1
1
AIR
TENP PLSTC COEC TIT
1
2. 1650
SENSOR, AIR PRESSURE
23522322
SENSOR ASS¥. AIR TURBO BOGST DDEC ZV
5182977
RZNS, SEAL (3.3055)
23522719
BOLT 145 0.8 X 20.0 LG HEX kiD
1
1
2
2. 1702
COVER, ZNkJECTORHARASS
8829508
COVER
1
2. 1720
HARI_5S,
23524280
5101020
8929534
11503454
11504985
11509511
1
9
t
1
4
2
2. 1847
SENSOR, AIR TEI#PERATURE
23515250
SENSOR ASSY.
2. 1900
TRIP
R23515448
ENGINE SEI_
TO DISC_CT
HARNESS ASSY. , ENGINE SENSOR
STRAP, NYLON (2.5255)
CI-ZP
BOLT, MlO X 1.5 X 20.0
BOLT, N8 X 1.25 X 14 NN
BOLT, N8 X 1.25 X 20 Nil
RECORDER ANALYSIS CONTROL SYSTEM
RENANUFACTURED 23515448
9
AR
D [ T RO 1" T
D Z E S E L
CUSTOM PARTS CATALOG 03/21/00
06R0534978
PART #
NAN[ AND DESCRTPTZON
QUANTTTY
2. 10008
- ZNdECTOR CONTROLS ELECTRONZC
P.23515849
RENANUFACTURED23515649
R23515668
PRO DR'rvER pETERBILT FLUSH MT
R2351_S69
PRO DRTVER KENWORTH FLUSH MT
R23515870
pRO DRI"VER FREIGHTLZNER FLUSH 14T
R23518671
PRO DRIVER VOLVO FLUSH liT
R235156"/2
PRO DRIVER FORD FLUSH NT
R23516428
FRO DRZVER K[14HQRTH SURFACE NT
23515448
PRO DRZVER DETROTT DI'ESEL FLUSH 141"
23515649
PRO DRZVER DETRQZT DZESEL SURFACE MT
2. 2000
-
AR
P4_
AR
AR
AR
AR
AR
AR
AR
FUEL PUSP
2.2001
_
ASSY. , FUEL
SEE ASSENBLY BREAKDOMN PAGE A1.
2350"7409
PUMP ASSY., L.H.
(GEAR CASE DRVN)
2.2010
BODY, FUEL PUMP
23506553
pLUG, STL 1/8-27
23511956
KZT, STATOR
23511981
•
STATOR, FUEL PUMP
2.2012
PXH, ALZGNI4[NT
23500694
PZN, ALZGI_IENT
2.2030
COVER, FUEL PUilP
2_1
SCREW
23508552
PLUG 3/8-18
PLASTTC F/PUI4= BARNES $60
23506561
PLUG
23511955
KZT, FUEL PUMP COVER
2.351195"7
COVER, FUEL PUMP ....
1
1
AR
1
2
8
2
1
AR
_........._1 ............................
2_2040
GASKET, FUEL PUMP COVER ................
2350654"7
GASKET, GOLD
23506548
GASKET, SZLVER
2351611?
GASKET, BLUE
23516;118
GASKET. N4BER
2.2060
BEAB:ZNG, FUEL PUMP
8923526
BEARZNG, FUEL PUMP
2.20?0
SEAL, FUEL PUI4P OZL
23512243
SEAL, UZL SGL LZP
2,2087
GEAR, FUEL PUMP DRZVE
23511959
GEAR (.275)
23511983
KEY,FUELPUMP
DRV. GEAR
8923522
RZNG, GEAR RETAZNZNG
2,2088
GEAR, FUEL PUMP DR]CVEN
3923521
pZN, DRZVEN GEAR
8923522
RZNG, GEAR RETAZNZNG
2.2089
SHAFT, FUEL PUMP DRZVEN
A SHAFT ASSy. XNCLUDES GEAR ROT SOLD SEPARATELY.
23511960
SHAFT
2.2093
SHAFT, FUEL PUMP DRZV[
A SHAFT ASSY. I'NCLUD[S ][TENS ZN 2.2093.
33511888
SHAFT, DRZVE
2.2130
VALVE ASSY.,
FUEL PUMP
33506580
SPACER, RELZEF VALVE
23506563
KZT, RELZEF VALVE (CONTAZNS VALVE, SPACER AND PZN
23506564
PZN, SHEAR RELZEF VALVE
8923528
VALVE, F_L _
2.2180
SPRZNG, FUEL PUMP VALVE RETAZNZNG
23506557
SPRZNG. RELZEF VALVE
2,2170
PLUG, FUEL PUMP VALVE
23506555
CAP, RELZEF VALVE
2.2180
GASKET, FUEL PUNP VALVE FLUG
23506556
SEAL RELZEF VALVE
2.2292
HUB FUEL PUI_ DRTVE GEAR
23511964
COUPLZNG, FUEL PUMP
R23807409
REN_R WACTURED 2350'7408
8925832
ELBOW, 90 DEG. 3/8 ZNV FLD TImE 3/8 PZPE (12.9480)
23506222
BOLT. 148 X 1.25 X 20 12 PT.
2.2007
GASKET, FUEL PUNP TO ENGZNE OR DRZVE ASSENSLY
5150193
GASKET (FUEL PUMP TO DRZVE ASS'(.)
10
(5.1010)
AR
AR
AR
AR
4
2
2
1
2
1
2
1
1
1
AR
1
1
1
1
1
1
AR
2
3
1
D E T ROT
T
D ][ E S E L
CUSTON PARTS CATALOG 03121100
06R0534878
PART #
2.2000
-
NAME AM) DESCRZPTZON
QUANTZTY
FUEL PUMP
2.2230
COUPLING,
8829479
FUEL PUNP DRZVE
COUPLZNG
1
2.2240
DRZVE ASSY., FUEL
SEE ASSEMBLY BREAKDOMNPAGE B1.
8929253
SEAL, RZNG .139" X 4.609"
Z.D. (2.2280)
8829785
DRZVE ASSY.
2.2001
DRZVE ASSY., FUEL
23513205
ELBOW, 90 [MEG. 3/8" FL TUBE 3/8" PZPE
8924175
ELBOW, 90 DEG. 3/8" STREET (12.9480)
2.2255
GEAR, FUEL _
DRZVE
8929788
GEAR, 15.8"/5 IOI 1:.0.
8411502
RTNG, RETAZNZNG (2.7470)
2.2260
ADAPTOR, FUEL PUNP DRTVE
8929474
ADAPTOR FUEL PUI_o 5RG SUIT SGO
2.2282
HUB, FUEL pLiNp DRZVE GEAR
882878-/
HUB, 15.875 MB LD.
11504822
BOLT,1148
X 1.25 X 30
2.3000A
-
FUEL FTLTER _
2.3010
ELEMENT,
23518481
2.3080
COVER,
5148023
892451-/
11505299
FUEL 5TRAZNER
COVER
PLUG, 3/8"-18
SQ. SOC. VZBRA SEAL (12.9550)
BOLT, NlO X 1.5 X 30.0 101
FUEL FZLTER
FZLTER,
FUEL SECONDARY
FUEL FlrLTER
VALVE ASSY. ,FUEL SHUTOFF
COVER
SENSOR ASSY. , nZL WATER FUEL & AZR TEMPERATURE
BOLT, NIO X 1.5 X 30.0 144
- FUEL LXNES _
1
5
1
3
2
AR
AIR
AR
1
1
1
2
AR
AR
AR
AR
AR
AR
AR
FUEL COOLER
2.5006
VALVE,
2350872"/
23518523
FUEL SUPPLY OrlEO(
VALVE ASSY, FUEL CHECK 3/8" NPTF
COM_ ASM.9/16-18
X 1.332 STGT
2.5060
HOSE,
BAHH0156
8929831
8823832
FUEL PUMP ]INLET
HOSE ASSY., //6 X 17.9 H&H
COMCECTOR, STRAZGHT 3/SFLD TUBE 3/8
ELBOW, 90 DEG. 3/8 ZNV FLD TUBE 3/8
2.50-/0
STRATNER TO FUEL PUMP
CLEP,
1
1
2.3590
SEPARATOR, FUEL WATER
23514047
PROCESSORASSY., FUEL PRO 380 12V HEAT
23515125
PROCESSORASSY. , FUEL PRO 380 NO HEAT
23518638
PROCESSORASSY. , FUEL PRO 380 24V HEAT
23521528
KILT, ELEMENT & GRONNET W/SEAL RZNGS 380/382
23516639
KTT, FUEL PRO 380E NO HEAT M/O DZVERTER CAP
(M/MOUNTZm I'IARDMA_ )
23516640
KTT, FUEL PRO 380E 12V HEAT W/O DZVERTER CAP
( M/N0UNTXNG HAR_ARE )
23518641
KZT, FUEL PRO 3805 24V HEAT W/O DZVERTER CAP
(MIMOUNTXNGHARDMARE
)
2.5000A
1
t
1
2.3305
FUEL/AZR SEPARATOR
23515444
PRO-CHEK FUEL/AZR SEPARATOR SZDE lilT
23513543
PBO-CHEK FUEL/A][R SEPARATOR REAR NT
23513542
@
ZNSTALLATZON KZT FOR PRO-Of.K SZDE NT
0 TNCLUDES HOSES N¢D HARDWARENECESSARY TO RETROFTT EXZSTZNG ENGZNES.
2.3390
COVER,
235170-/5
5148171
23518002
11505299
1
1
STRAXNER
FUEL STRATNER
FTLTER, FUEL PRZNARY
2.3320
ELEMENT,
23518482
1
1
11
1
2
PTPE (12.9460)
PZPE (12.9480)
1
1
1
DETRO
X T
DX ES E L
CUSTOM PARTS CATALOG 03/21/00
08;R0534878
PART _
NAME ANO DESCRXPTXON
QUANTITY
2.5000A
- FUEL LZNE$ AN;) FUEL COOLER
2362448
CLZP .688" DTA 3/8"
BOLT CTD (12.8=;54)
11504986
BOLT, 148 X 1.25 X 14 1414
2.5115
HOSE, FUEL PUMP OUTLET TO COLD PLATE
BN,IP0311
HOSE ASSY., #6 X 33.5 u H&P
8925832
EL.BOW, 90 DEG. 3/8 _[NV FLD TUBE 3/5
2.5118
HOSE, COLD pLATE TO F1'LTER
5AHP0188
HOSE ASSY., #6 X 21,2"
H&P
23505247
TEE, 90 DEG 5/8" TUBE 2 MAY 1/4"
2.5121
CLTP, COLD PLATE TO FILTER HOSE
2362448
CLZP .588" DZA 3/8"
..............
1
1
pI"pE (12.9480)
PZPE (12.9615)
BOLT CTD (12.8554)
1
1
1
1
2
2.5160
HOSE, FZLTER TO CYLXND_R I_[AD
BAHP0213
HOSE ASSY., #6 X 23,7"
H&P
8529833
COI4_CTOR, 3/8"
INV. FL. TUBE; 5/8"
PTpE (12.5460)
8929*/25
ELBOW, .80" RESTRZCTZON, 3/8"PZPE
)(5/15"
(2.5210)
8929832
ELBOW, 90 DEG. 3/8 ][NV FLD TUBE 3/8 PI'pE (12.9480)
1
1
1
1
2.5180
CLZP, CYLZNDER HEAD TNLET
2382448
CLZP .658" DXA 3/8"
1
BOLT CTD (12.a5_4)
2.5255
SI'IZELDZNG, FLEXZBLE HOSE
5101020
STRAP, NYLON (2.5255)
2
2.5280
VALVE. FUEL SYSTEN SHUTOFF
....
_?--q_- _-R7......................
VALV-" 1_4_- NPTF ...........................................................
1
12
D ETRO
1"T
D T E S E L
CUSTON PARTS CATALOG 03/21/00
06R0534878
PART #
3.3000C
NM4E AND DESCRZPTZON
- AZR ZNTAKE NANZFOLD
3.3801
AZR ZNTAKE NANTFOLD
23517434
I_ZFOLD
AZR TNT HORZZ 1/2
11509526
BOLT, NlO X 1.5 X 130 m
11F_39798
BOLT, N10 X 1.6 X 70 IBi
8922327
pLUG, 1/4" NPTF (12.9S50)
8923916
PLUG, 1/2" PZPE (12.9550)
3.3803
GASKET,
23517875
3. SO00A
QUANTITY
SC BOSS EO
AZR ZNT_E NN_IZFOLD
GASKET AZR _rNT NFD STL RUB CTD $50/80
1
5
2
2
1
3
- TURBOCHARGER
3.5001
TUI_R
R2351S635
8829169
11506101
RENANUFACTURED 23515635
WASHER (12.9190)
I_JT, NIO X 1.5
1
4
4
3.5307
GASKET, TURBOCHARGER EXHAUST ZNLET COtWIECTZON
8929529
GASKET, TURBO EXHAUST ZNLET
1
3.5500
TUBE, TURBOCHARGER OZL SUPPLY
2351318";'
TUBE, TURBO QZL SPLY HZGH NT
8829833
CONNECTOR, 3/8"
ZNV. FL. TUBE; 5/8 _ PZPE (12.9480)
1
2
3.5502
CLTp,
5145994
1
TURBOCHARGER OZL SUPPLY TUBE
CLZP, 3/8" TUBE X 1/2"
BOLT
3.5505
TUBE, TURBOCHARGER OZL RETUgRN
23505038
TUBE TURBO OZL DRN FLEX STNLS
23_39
ELBOW, 90 DEG FLD 3/4 TUBE
11509511
BOLT, 148 X 1.25 X 20 ml
1
1
2
3.5506
8929285
1
GASKET, _R
3.5507
CLZP,
2476233
5173022
11503454
11509511
11507036
0ZL RETURN TUBE
GASKET (3.5505)
TURBOCHARBER OZL RETURN TUBE
CLZP, .7BO" DZA., 3/3"
BOLT
B_,
CLZP 90 DEG
BOLT, MIO X 1.5 X 20.0
BOLT, 148 X 1.25 X 20 ml
I_JT, 148 X 1.25
13
1
1
1
1
1
D ETRO
1" T
D Z E S E L
CUSTOM PARTS CATALOG 03/21/00
06R0534878
PART #
4. IO00A
-
NAME AND DESCRZPTZON
QUANTZTY
OTL PILN4P
4. 1001
PUMP ASSy.,
OZL
A PUNP ASSY. ZNCLUDES ][TENS I"N 4.1040,
4.1065,
4.1075,
R23505888
REMANUFACTURED 23505886
23505886
_
ASSY., RT. SZDE ENGZNE
23505895
DOWEL, SLEEVE OZL PLq4P
8929011
PTN. 25L.,
DOWEL
11502826
B0LT, 1410 X 1.5 X 40.0
8929393
BOLT, M10 X 1.5 X 70.0
(12.9001)
4. 1003
OVERHAUL KZT, OXL PUMP
AN OVERHAUL KZT "rNCLUDES ZTEMS ZN 4.1065,
23511065
OVEE_HAULKZT,
4. 1030
SHZM, OZL PUMP
23508"/40
SHZI4 (.OOfi5"
4.1075,
4.1090
4.1520,
AMD 4.1220.
AR
1
1
1
2
2
4.1590
AM) 4.1730
RT SZDE ENGZNE
1
THK. )
AR
4. 1040
BODY, OZL PUMP
BODY ASSY. TNCLLIDE5 BUSHZNGS ZN 4. 1050.
2_878
BODY ASSY. , RT. 5ZDE ENGXNF
1
4. 1050
BUSHXNG, OZL PUNP BODY
23505;979
BUSHZNG, SHAFT /U)RTVE GEAR
2
4. 1065
SHAFT AND _
23505682
ASSy. , OIL Pt.q4P OMI"VE
SHAFT & GEAR ASSY., OZL PUMP
..............................
+1..............................
4. 1075
SHAFT ANO GEAR ASSY.. OZL PUNP DRXVEN
..................
23507337
SHAFT & GEAR ASSY., OZL _
1
4. 1090
GEAR, OZL PUNP DRZVE
23505884
GEAR, 89 TEETH
1
4. 1220
COVER, OZL PUMP
A COVER ASSY. TNCLUDES BOSHZNGS ZN 4+ 1220
23505883
COVER ASSY, OZL PUre=
23505979
BUSHZNG, SHAFT &DRTVE GEAR
11509511
BOLT, N8 X 1.25 X 20 Ji
11509514
BOLT, M8 X 1.25 X 50 Ill
1
2
2
2
4. 10009
-
OZL DZSTRZDUTZON SYSTEM
4.15t0
PZPE,
23506683
11509514
OZL PUNP TNLET
TU_E & SCREEN ASSY, OZL PUMP
BOLT, 118 X 1.25 X 50 JI4(
4.1520
GASKET, OIL
23505982
4+ 1540
BRACKET, 01L
8929104
11505258
11502812
PUMP INL_" PTPE
GASKET, OZL /NLET TUBE TO pUMP
PUMP SCREEN SUPPORT
BRACKET
BOLT, 1410 X 1.5 X 30.0
NUT, NIO X 1.5
1414
4. 1580
PZPE, QZL PUMP OUTLET
23505880
TUBE, OZL PUMP OUTLET
23514'76?
NS
EL.BO_ ASM OZL _[NL 8. PRESS RLF VLV $60
4. 1580
PZPE, OZL PUMP OUTLET
23514738
ELBOW, OZL XNL & RELZEF VALVE
457008
PZN, 3/16" X 1-1/2 u SPRTNG (12.9270)
4. 1620
SPRZNG, OZL PUMP OUTLET PZPE BYPASS VALVE
512632?
SPRXNG (2.96"
FREE LENGTH, 15 COZLS, CLQSEO ENOS,
4. 1830
VALVE, OZL PUNP OUTLET PI'PE BYPASS
8922740
VALVE
5117957
SEAT
23505891
RZNG SEAL, OTL PUMP OUTLET
23505852
RZNG SEAL, OIL PUMP TNLET
11504822
BOLT, 148 X 1.25 X 30
14
1
2
1
2
4
2
1
1
1
1
1
1
1
1
1
2
DETROZT
DTESE
L
CUSTOM PARTS CATALOG 03121100
06R05:34878
pART #
4. 100015
- OIL
NANE AND DESCRZPTZON
QUANTZTY
DZSTRZBUTZON SYSTEM
4. 1590
GASKET, OZL PUMP OUTLET PZPE
8928347
GASKET (TO BLOCK)
4. 1000C
t
- OZL PRESSURE REGULATOR
4. 1870
REGULATOR, OZL PRESSURE
A PILMp KZT INCLUDES PUMP ASSY. AND SEAL RTNG.
23012901
REGULATOR ASSY.
4.1080
BODY, OZL PRESSURE REGULATOR N_) RELZEF
457008
PZN, 3/10" X 1-1/2"
SPRZNG (12.9270)
8929283
BODY, REGULATOR
4. 1690
SPRI"NG, nZL PRESSUR[ REGULATOR
0128327
SPRZNG (2.96"
FREE LENGTH, 15 CUzLS,
4. 1700
VALVE, 01'L PRESSURE REGULATOR
8922740
VALVE
4.1701
SEAT, OZL PRESSURE REGULATOR
23012900
SEAT
11504822
BOLT, 148 X 1.25 X 30
4. 1671
RELZEF, VALVE OZL PRESSURE
A PUMP KTT ZNCLUDES PUMP ASSY. AND SEAL RING.
8921080
VALVE ASSY.
4. 1680
BODY, OZL PRESSURE REGULATOR AND RELZEF
457008
p1rN. 3/15" X 1-1/2"
SPRZNG (12.92"/0)
8921084
BODY,
RELZEF
4. 1590
SPRZNG, OZL PRESSURE REGULATOR
0120327
SPRZNG (2.90"
FREE LENGTH, 15 CUZLS,
4. 1700
VALVE, OZL PRESSURE REGULATOR
8322740
VALVE
4. 1701
SEAT, OTL pRESSURE REGULATOR
0117957
SEAT
11504822
BOLT, 1_8 X 1.20 X 30
4.2000A
1
t
CLOOED ENDS,
1
1
1
2
1
1
1
CLOSED ENDS,
1
1
1
2
- OZL FTLTER
4.2250
ELEMENT, OZL FZLTER
23018480
FZLTER,
LUBE OZL SPZN ON
4.2291
ADAPTOR, 01'L FZLTER COVER
8923847
PLUG, PZPE 1/4-18"
4.4000A
1
2
MrI'F
1
- OTL COOLER
4.4001
CORE, OTL COOLER ENGZNE
0247436/
CORE ASM ENG OZL CLR 10 PLT $60
1
4.4050
HOUSING, OI"L COOLER-ENGINE
23018638
HOUSTNG
ASMDIlL CLR 10 PLT 12L $80
4.40r-'_D HOusIrNG,OZL COOLER-ENGZRE
8922327
PLUG, 1/4" M:TF (12.9550)
23011573
PLUG, 3/4"
PZPE SQ. SOC. SCOTCHGRZP
23511074
PLUG, 1" PI"PE SQ. SOC. SCOTCHGRTP
23011073
PLUG, 3/4" PZPE ED. SIX:. SCOTCHG_ZP
23010104
PLUG PZPE 1/4-18
HEX HD STL CTD RED
1
4
1
1
1
4.4053
HOUSZNG, OZL TRANSFER COOLER-F][LTER ADAPTOR
23508302
RZNG, SEAL
1
4.4050
GASKET, OZL COOLER HOuslrNG
8029289
RI'NG, SEAL
1
4.4110
ADAPTOR, 01"L COOLER
AN ADAPTOR ASSY. ZNCLUDES 4-PLUGS ZN 4.4110
PLUS ZTEMS "rN 4.4140
23518040
his #
ADAPTOR ASN OZL CLR/FLTR IOPLT 12LS80
4.4001
CORE,OlrL COOLER ENGINE
02474387
CORE ASN ENG OZL CLR 10 PLT S80
4.4030
GASKET,OZL COOLER CORE ZleqlER
23506247
GASKET, OZL COOLER HOUSTNG
19
1
AND 4.4150
1
1
1
DETRO
Z T
DZESEL
CUSTOIq PARTS CATALOG 03121100
06R0534379
PART #
NAME AND DESCRZPTIQN
QUANTITY
4.4000A
- OIL COOLER
4.4050
HOUSING,OIL
COOLER-ENGINE
23507182
BOLT, SPL 148 X 1,25 X 73.0
23518638
HOUSING ASN OIL CLR 10 PLT 12L $80
23507183
BOLT, SPL N8 X 1.23 X 93.0
4.4110
ADAPTOR,OIL
COOLER
23518637
ADAPTOR PSI# O/CLR 10 PLT PF2100 FLTRS
23508392
RING, SEAL
23505062
BOLT, MlO X 1.5 X 40
# NOT SERVICED, USE COMPONENTS.
3
1
7
1
2
4
4.4112
GASKET, ADAPTOR TO OIL COOLER HOUSING
23505902
RING. SEAL BYPASS FILTER
4.5000A
1
- OIL FILLER
4.5070
COVER, 01rL FILLER HOLE
23507284
COVER
23511574
PLUG, 1" PIPE SQ. SOC. SCOTCHGRZP
11509511
BOLT, M8 X 1.25 X 20 NEE
1
1
4
4.5090
GASKET, OIL
8929302
1
4.6000A
-
FILLER HOLE COVER
GASKET, 4 HOLE (4.5007)
DZPSTTCK
4.S001
DTPSTTCK
23506487
.
S .......
..........................
84;= _ER
DIPS'rICK,
SEAL AND 23513683
4.6020
GUIDE,
23513883
23513842
TURNTITE
{X-31.49",
Y-t_O3"_..ZT2S.71")
ADAPTOR...............................
DIPSTICK
GUIDE
SEAL OIL
1
1
LVL GA ADAP
4.6030
ADAPTOR, DIPSTICK
23506489
ADAPTOR, OIL TUBE
23r'_)6485
B*
"TUBE ASSY, OIL LEVEL TURNTITE
137401
NUT, 1/2" INV. TURE
* INCLUOE NUT IN 4.6030
B NOT SERVICED, FOR SERVICE USE 23515136
DIPSTICK,
23515135
942 COPPER SEAL AND 23513883
ADAPTOR.
4.8040
CLIP,
5153473
5145872
106281
11509511
11507036
...........
.................1.........................................................
1
1
t
TUBE ASSY.,
23513
DIPSTICK
CLIP, t/2"
TUBE, 3/9 BOLT
BRACKET CLIP,
90 DEG.
WASHER. 5/18"X3/4"
BOLT, 148 X 1.25 X 20 _
NUT, 148 X 1.25
1
1
1
1
1
4.7001
PAR, OIL
OIL PAN ASSYS. INCLUDE PLUGS, INSERTS,
SEAL RINGS, AND NUTS IN 4,7001
23521330
KIT TNSERT OIL PAN
23522253
PAN ASSY., OXL_ P.I_'_
8923313
PLUG, 3/4"
PIPE (12.9550)
5178994
PLUG, 3/4"-14
NPTF PIPE (4.7080)
23520929
SEAL RIHO
23522231
SLEEVE ASSY.,
OIL PAN BOLT MOll SEAL SYS
3
1
3
1
3
10
4.7030
GASKET, OIL
23532279
1
4.7000A
4.3000A
- OIL PAN
PAN TO BLOCK
GASKET, OIL
PAN 'd/O CORD MOD SEAL SYS
- VENTZLATING SYSTEN
4.8001
PIpE
23505906
23523931
ASSY. BREATHER
TUBE,BREATHER
DRAFT
HOSE, 1,100 I"D X 2.50
LG
18
1
1
DETRO
ZT
DZ ESEL
CUSTOM PARTS CATALOG 03/21/00
(_053487B
PART #
4.8000A
NAME AND DESCRZPTZON
QtJANTZTY
- VENTZLATZNG SYSTEM
4.8039
CLAI_,
5186840
BREATHER TUBE
CLAN , 1 1/2"
4.8040
CLI"p,
5173022
23506443
11504822
11S09511
23511786
5157412
11BO7036
BREATHER TUBE
BRACKET, CLIP gO DEG
CLZP, #16 HOSE 1" DZA. (4.8183)
BOLT, N8 X 1.25 X 30
BOLT, 148 X 1.25 X 20 14
BOLT, MlO X 1.5 X 25.001M
(12.9001)
SPACER, 7/8"X13/32"X1/4
"
NUT, N8 X 1.25
I.D.
17
(12.9660)
2
1
2
1
1
1
1
1
D E T R 0 lr T
D 1" E S E L
CUSTOM PARTS CATAI.0G 03/21/00
06R0534878
pART #
5. 1000
-
NA_
AND DESCRI"PTI"ON
FRESH WATER
5. 1001
PUMP ASSY.,
FRESH WATER
A PL_
KIrT ZNCLUDES PUMP ASSY, A_ SEAL RZNG.
23518215
NS
PUMP ASM WAT RR GRCASE SQCUT O-RG $60
5. 1030
BODY, FRESH WATER PUMP
23511573
PLUG, 3/4"
PZPE SQ. SOC. SCOTCHGRI"p
23511574
PLUG, 1" PZPE SQ. SOC. SCOTCHGRZP
23517027
BODY WAT PI_ RRGRCASE SQCUT O-RG $80
8929594
PLUG, 3/8"-18
DZA. P][PE EXT. i'_X. SOC.
5. 1031
COVER, FRESH MATER PUMP BODY
8g22383
COVER, NON-METALLZC
5. 1032
GASKET, FRESH WATER _
COVER
23512045
SEAL RZNG
8922407
R'rNG
RETAZNER
5, 1050
SHAFT ASSY.,
FRESH WATER PU_
23505898
SHAFT
5. 1070
BEARZNG, FRESH WATER PUMP
8929422
BEARZNG ASSY.
5.1071
RETAZIER,
FRESH WATER P_
BEARZNG AND.SEAL
8929427
RI"NG
5.1110
TMPELLER, FRESH WATER PUMP
23517573
ZMPELLER W/PIqP C/Z 6 VANE $50
5. 1130
SEAL, FRESH WATER PUI4P
23518316
SE[AL WAT PUMP UNZTZZE[D S60 W/SEALANT
8929134
SEAL, LTp TYPE[
5. 1190
GEAR, FRESH WATER _
DR][VE
2350559'7
....
WA.T_R, $PL WAT PUI_ GEAR (5. 1110)
....
QU.4NTlrTy
23508583
2352:_?07
23505025
11509523
23505755
....
BOLT, M12X1.75X50.
OMM
(R) KZT, WATER PU_ MT RR GR CASE
SEAL RING W/SQ CUT (5. 1032)
BOLT, 1410 X 1.5 X 55 MM
BOLT, NIO X 1.5 X 155.0
1
2
1
1
1
1
1
t
1
1
1
1
1
1
1
1
1
1
1
2
5.1002
RECONDZTZONZNG KIT, FRESH WATER PI.INP
A RECONDZT][0NING KZT ZNCLUOE5 SEAL RZNG ZN 5. 1001, BEARZNG ZN 5. 1070 LOCY,RZ
NG I"N 5.1071
A_ ZTENS XN 5.1130
AND 5.1236.
23509105
KZT, RECONDZT'Ir(M4XNGM/SQ CUT NAT PMP & CVR SEALS
AR
5.2000B
- 11_RMOSTAT
5.2050
THERNOSTAT ASSY.
89298"/8
THERMOSTAT ASSY.
5.2060
SEAL,
5132155
23509514
190 DEG. OPENZNG TENP.
THERMOSTAT
SEAL
SEAL FLANGE
2
AR
5.2120
COVER, THERMOSTAT HOUSZNG
8925728
COVER
23511572
PLUG, 1/2" NPTF Sq. SOC, (12,9550)
23511573
PLUG, 3/4" PI'PE SQ. SDC. $COTCHGRZP
5136240
PLUG CAP .42" DZA. (2.2001)
8524140
DRAZNCOCK, 1/4"
(12.9510)
23505050
BOLT, NIO X 1.5 X 85
5.2000(:
2
1
2
2
1
1
4
- WATER BYPASS TUBE
5.2160
TUBE,
23505898
WATER BYPASS
TUBE
5.2165
HOSE,
8925875
WATER BYPASS TUBE
HOSE, 1 314"
X 3.25 a
2
5.2150
CLlrp,
23505048
WATER BYPASS TUBE
CLAMP, 2"-2
1/2"
4
5.30008
1
- WATER (_)NNECTIONS
13
DZA. HOSE
_
DETRO
TT
DTESEL
CUSTON PARTS CATALOG 03/21/00
06R0634978
PART #
5.3000B
NAME AND DESCRI"pT1rON
QUANTI"TY
- WATER COIk_CTZONS
5.3400
TUBE,
23505999
WATER PUNP TO 01"L COOLER
TUBE(FORHZ & NED14T.TURBO)
5.3401
HOSE,
23506325
WATER P_
TO OTL COOLER
HOSE, 2.75"X3.0"
L (BLUE)
2
6.3405
CLZP.
8929865
WATER PUNP TO OTL COOLER TUBE
CLN4P, 3"-3
1/2" I'D HOSE
4
5.4000A
5.4010
I_
1
- FAN
BLADE,
FAN HTGH LOt/ AJk_)CRA_
NOUNTED
( CUSTONER FURNZSHED)
BLADE
6.4015
PULLEY A/_
8929168
8929218
9925585
9409036
5.4025
SUPPORT,
23511356
11504822
11509925
11500531
11508533
11513960
HUB ASSY., FAN
WASHER (12.9190)
PULLEY, FAN 3 GROOVE 203.0,
1 GROOVE 254.0
BOLT, NIO X 1.5 X 380.0 (12.9001)
BOLT, 3/8"-24
X 1.125"
(12.9001)
1
6
1
1
8
FAN NOUNT][HO
SUPPORT, W/UPR RT BOLT BOSS
BOLT, 148 X 1.26 X 30
BOLT, NIO X 1.5 X 110 144
BOLT, N14 X 2.0 X GO lel
BOLT, N14 X 2.0 X 100 1414
BOLT, NIO X 1.5 X 145 m4
1
5
2
1
1
I
5.4102
SpI'NDLE ASSY., FAN ERTVE
A SPZHOLE ASSY. I'NCLLIOES ][TENS ZN 5.4102,
5.4103,
6.4111
AND 5.4160.
8925538
SPZNI3LE ASSY.
465322
FZTT][HO, 1/8" VENT (12.9540)
271283
FZTT][NG, 45 DEG.-1/8"
GREASE (12.9540)
455734
PZN, SPRZNG 1/8" X 3/4"
(12.9300)
11500944
BOLT, N12X1.75X40.O
ml
5131978
WASHER, .53 X 1.00 (1.5001)
9929214
WASHER
1
1
1
1
4
4
1
6.4103
HOUS][NG,
9929215
8520419
FAN DRZVI_ SPZtE3L._
PLATE
BOLT, N10X1.5"X45.O"
1
1
5.4111
BEARTNG,
7451005
23506569
8929064
23518178
8929063
8829218
FAN SPZHOLE
BEAR][NG,
ROLLER
(12.4048)
BEARING, BALL (OPTZQNAL TO 8329530)
RZNG, ZNT RETAZNZNG 3.121"
O.D. (12.4048)
BRG BALL ALT DRZV HEAT STASTLZZED $80
RZNG, ZNT RETAZNZNG 3.734"
O.D. (12.4048)
RZNG, ZNT RETAZNZNG 1.618"
Q.D. (5.4111)
6.4160
SEAJ-, FAN SPZNDLE
8828213
SEAL
SPECTAL (1.2070)
1
1
1
1
1
1
1
15
DETRO
ZT
DT ESE L
CUSTOM PARTS CATALOG 03/21/00
06R0534878
PART #
7. IO00A
NANE AND DESCRZpTlrON
QUANTZTY
- BATTERY CHARG][NGGENERATOR
7. 1001
GENERATOR ASSY.
19010182
GEN CI-_G AC 24V70A NG CT#/CCW215X
442733
BOLT, 1/2"-13
X 1.25" (12.9001)
9427945
BOLT, 1/2"-13
X 6.25"
(12.9001)
5132715
WASHER, .53"X.94"X.
12" (1.3140)
103323
LOCKWASHER, 1/2"
10283/
NUT, 1/2"-13
1
1
1
5
2
1
7. 1500
PULLEY,
51400"/0
1
"7. 1575
BELT,
23519070
"/.1580
STRAP,
23514316
23511669
103345
11501055
GENERATOR
PULLEY,
3.86"
DTA, 2 GRVS .500"
WTDE
C_NERATOR DRTVE
BELT SET 2/HC50
1
GENERATOR _ZNG
ROD, AD_JUSTZNGM16 X 2.0
LZlq_, ADdUSTING ROD
WASHER, 5/8"
NUT, M18X2.0
X 222.0
LG
7. 1595
BRACKET. GENERATOR MOUNT'rNG
23521125
BRACKET, C'_RATOR LOW NT
23521130
BOLT NIO 1.50 X 145.0 NEX FLG CTD
892935"/
BOLT, NIO X 1.5 X 120 (12.9001)
23521131
NUT MlO HEX FLANGE
7.3000A
1
1
2
2
1
2
1
4
- STARTI'NG MOTOR
7.3001
NOTOR ASSY.,
R0481128
104"/8980
9438"/20
103325
5TARTZNG
MOTOR ASSY., 24V 42NT (RI_FACTURED)
MOTOR ASSY. (24V. CW. ZNSUL. 42M1")
BOLT, 5/8"-11X2
1/4 m ( 12PT. ) (12.5005)
LOCKWASI-IER,5/8 _
21
AIR
1
3
3
DETRID
ZT
DT ESEL
CUSTOM PARTS CATALOG 03/21/00
06R0534878
PART #
"ll.lO00A
NAi4E AND DESCRIPTION
_JANT1"TY
- ENGI"NE NOUNTTNG BASE
11 . 10"/0
SUPPORT, ENG;ZNE FRONT
89:297744
SUPPORT (WEST COAST) 1"TEN 1
11509528
BOLT, M12 X 1.775 X 30 _
8929068
BOLT, M14 X 2.0 X 140 (12.9001)
22
1
8
4
TYPE BREAKDOWN
FIG.
SERIES
_2.800oA
SUPPUES/MAINTENANCE
PRODUCTS
PART
NO.
60 PARTS
CATALOG
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8001
PAINT, ENGINE TOUCI'kUP
8_9665
PAINT,_-UE (X GAL. CAN)
_,R
IL_9666
8929667
PAINT,BIUE 02 OZ. SPRAY CAN)
PAIN'S,CLEAR (1 GAL. CAN)
AR
AR
Rg_
__'_668
PAINT.CLEAR (12 OZ- SPRAY CAN)
AR
12.8005
KIT, RLTIER
MAINTENANCE-FUEL/OIL
23518018
lOT, FitTER MAINTENANCE $50/60
Wt23516189 PRIMARY
KIT, RLTER MAINTENANCE $60
(PRE-1993)
KIT,RLTER MAINTENANCE $50/60
23518683
23518686
AF
AF
AF
(1993-)
12.8006
FUEL SYSTEM PRODUCTS
23520047'
FILTERASSY.PRB/,ARY30 MICRON
SEA PRO 150
ELEMENT PRtMARY3OM_C_NSEAPRO 300
PROCESSOR ASSY., FUEL PRO380
NO HF_AT
23518168
23515125
AF
AF
A1
AF
23519956
PROCESSOR _.,
NO HEAT CHROME
R.Rt PRO 380
A1
AF
23514047
PROCESSOR ASSY., FUEL PRO 380
12V HEAT
PROCESSOR ASSY., FUEL PRO 380
12VW/GROUND
PRO-CHEK FUEUAIR SI_PARATOR
REAR MT
A1
AF
A1
AF
23516638
PROCESSOR ASSY., FUEL PRO 380
24V HEAT
A1
23513542
INSTN_LATIONKIT FOR PRO-CHEK
SIDE MI"
PROCESSOR ASSY.,.FUEL PRO 380
12VW/FLUID HEAT
PRO-CHEK FUEL/AIR SEPARATOR
SIDE MT
A1
23519724
WROCESSORASSY., FUEL PRO 3_0
24V W/FLUID HEAT
A1
I_R
23S21056
PROCESSOR ASSY., FUEL PRO 380
12V HF_ATW1F SENSOR
PROCESSOR ASSY. _
PRO 38O
1L_/11_,/HEAT
K_, FUEL PRO 380E NO HEAT W/O DIW=H_I:FLCAP
A1
_:l
A1
AR
A1
&R
23516640
K_, FUEL PRO 380E 12VHEAT W/O
DIV_m ,'_ CAP
A1
AR
23516641
KIT, FUEL PRO 380E 24V HEATw/O
DIVP-HtP-_CAP
Kn_,FUEL PRO 380F 12VW/O D_W:H i'l=RCAP
_ FUEL PRO 380 24V FLUID HEAT
W/O D_v=m =H CAP
Kff, FUE_ PR0 380E NO HEATW/DI'4EHi _ CAP
A1
A_
A1
ALq
A1
AI_
B1
AF
23519238
K_, FUEL PRO 380E 12V HEAT
CHROME W/DIVER'_R CAP
B1
AF
23519235
KFE,FUEL PRO 380E 12V HEATW/DIVE_IcH CAP
KrE,FUEL PRO 380E 24V HEATW/DIVERTER CAP
B1
AR
23521049
23513543
23519¢Jb"7
2351.¢*.A.*.
23520907
23516639
23519239
23519725
23519237
23S19236
12.8000A
S UPPLIES/MAIN
t P..NANCE
AF
AF
AF
AF
_=l '
B1
PRODUCTS
esp_
_
© 1998 IY_[ROIT D_F.L
CORPORATION
SERIES
60 PARTS CATALOG
TYPE BREAKDOWN
12._e0A
FIG. PART
NO.
A
SUPPLIES/MAINTENANCE
PRODUCTS
ASSY.
SECT.
NAMEAND DESCRIPTION
12.8006
FUELSYSTEMPRODUCTS
(cont.)
23519778
KIT FUEL PRO 380 12V/120V HEATW/
DIVEK_EH CAP
V4RENCH,COLLAR FUEL PRO 380
(REMOVAL ONLY)
KIT,12VHEATERUPGRADE
(LONG
CAN)
KIT, 24V HEATER UPGRADE (LONG
CAN)
23516731
23518360
23518361
AR :
AR
AR
AP,
12.8025
OIL, ENGINELUBRICATING
ATFBULK
BULK MOBIL MUL"R-PURPOSE ATF
ATFDRUM
55 G/U- MOBIL MULTI-PURPOSE ATF
ATOLL
",GAL. PAIL MOBIL MULTI._°URPOSE
ATF
12 QUART MOBIL MULTI-PURPOSE
ATE
.......
A'IrFQUART
............................
B1
AR
!
AR
AR
GRFJ_SEC
...............
_6x_4_Z__,_I=D_G_'_iL: ......
......
GREASED
GRm'.SE
AR
AR.......
GREASE SPECIAL .......
400 LB. DRUM MOBILGREASESPECIAL
I
JAR
.OBILGREASESPEC,AL
AR
AR
HPCART
60X14 OZ. CARTRIDGES MOBILGREASE
HP
HPDRUM
400 LB. DRUM MOBILGREASE HP
HPKEG
MOBIL424
120GAL.
LB. KEG
MOBILGREABEPIP
55
MOBILFLU[D424
AR
ARAR
E
GHC._0D
375 LB. DRUM MOBIL3RANBSHC 50
I/ AR
SHCSOK
SHCSOP
23512703
120 LB. KEG MOBtLTRANS SHC 50
35 LB. PAILMOBILTRANBSHD 50
1 GAL. DELVAC1300 SUPER 4 CYL
END
AR
23512704
55 GAL. DELVAC1300 SUPER 4 CYL
ENG
23512740
23512741
BULK DELVAC1300 SUPER 4 CYL ENG
5 GAL, DELVAC1309 SUPER 4 CYL
ENG
23518542
55 GAL. SUPER GEO NATURALGAB
ENGINE
23520320
55 GAL. POWER GUARD DELVAC1 4
CYL ENG
....
7_Ng0D
75Wg0K
400 LB. DRUM MOBIU,._E SHC T5wg0
120 LB, KEG MOBILUBE SHC 75W90
75¥1g0P
35 LB. PAILMOBtLUBE SHC 75W_)
80WldOD
AR
80Wl 40K
400 LB. BARREL MOBILUBE SHC
80W140
1201t3. KEG MOB}LUBESHC 80W140
80Wl 40P
B0Wg0D
35 LB. PAIL MOBILU_ SHC 80W140
400 LB. DRUM MOBILUBE HD 80W90
AR
AR
80Wg0K
120 LB. KEG MOBILUBE HD 80W90
AR
89_tcJOp
85W1400
35 IB. PAILMOBILUBE HD 80W90
400 LB. DRUM MOBILUBE HD 85W140
AR
85W140K
85W140P
120 lB. KEG MOBILUBE HD 85W140
35 lB. PAILMOBILOBE HD 85W140
AR
AR
Al/ tnf_
.cab;eiff
to changewlthoutnotice,All rightsreserve_
6SP161 9809 © 1998DETROIT DIESEL CORPORATION
12.8000A
=
i
I AR
I AR
AR
4
AR
AR
AR
SLIPPLIEStMAINTENANCE
I
PRODUCTS
TYPE
BREAKDOWN
SERIES
12.8000A
FIG
SUPPUESAMAINTENANGE
PRODUCTS
PART
NO.
A B C
60 PARTS
I
:
CATALOG
J
vl
NAME AND DESCRIPTION
(Note: Assemblies
for component
are shown
reference
only.)
12.8006
23515125
23514051
23516794
23516796
23514060
23516795
23514048
23514061
FUEL SYSTEM
PRODUCTS
PROGESSOR ASSY.,FUEL PRO 380
NO HEAT
PROCESSORASSY., FUEL PRO 380
NO HF.ATCHROME
PROCESSORASSY., _
PRO 380
12V HEAT
PROCESSOR ASSY.,FUEL PRO 380
12V W/GROUND
PROCESSOR ASSY.,FUEL PRO 380
24V HEAT
PROCESSOR ASSY.,FUEL PRO 380
12V W/FLUID HEAT
PROCESSOR A_..
FUEL PRO 380
24'4 W/FLUID HEAT
PROCESSOR ASSY., FUEL PRO 380
12V HEAT WIP SENSOR
pROCESSOR ASSY. FUEL PRO 380
12V/120VHEAT
K_, FUEL PRO 380E NO HEATWK) DIv_-;t m-1CAP
KIT, FUEL PRO 380E 12V HEATW/G
Dt_._t _.HCAP
K_, FUB. PRO 380E 24V HEAT W/O
DIVe-ITCH CAP
KIT, FUEL PRO 380F 12V W_DDF
V_.HjER CAP
t_T, FUEL PRO 380 24V FLUtDHEAT
W/O DIV=HZ_H CAP
STUD, 13/16"-12, 7/8-14
ELEMI_ff & GROMMET ASSY.380
(USE W_351405_ KiT)
KIT,W/CAP & BOWl-(3-RINGS
BRACKET,FUEL PRO 380 MOUNT
U-CLAMP
ASSY.,
FUEl.
PRO
380
SPRING, FUEL PRO 380
U-BOLT,FUEL PRO 380
COVER, CLEAR FUEL PRO 380
COLLAR, FUEL pRO 380
23516797
23517429
23SlAO43
23519958
23519943
23519944
WIRE HARNESS, FUEL PRO 380
TEE. t/4"NPTp
K_. W/CAP & SEAL RING
CIRCUIT BREAKEr, FUEL PRO 380
VALVE, CHECK INLET (23519966)
VALV_ CHECK THERM CONTROL IN-
23519959
TERMINAL, BUTT SPLICE FUEL PRO
380
VALVE,CHECK "nIERM CONTROL
W/GRD INLET (23S21066)
VALV¢:ASSY., DR._N FUEL PRO 380
=-is.biG, FIPE TO HOSE FUEL PRO
380
HEATER,FUEL PRO 380 12V
HEATER,FUEL PRO 380 24V
HEA'_R, FUEL PRO 380EE 120V
KIT, W/THERMOSWtTCH & TY-RAP
HARNESS, FUEL PRO 380 12V/24V
HARNESS, FUEL PRO 380 12V
GROUNDED
23519956
23514047
23S21049
_3S1_o38
23519957
23519724
23521 O56
235209(}7
23516639
23516640
23516641
23519239
23519"/25
23519934
23S14049
23517427
23517428
23521000
23517426
23517425
23521061
I
1
1
I
1
12.8000ASUPPLIES/MAINTENANCE
1
1
I
t
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
I
1
1
1
2
1
2
1
1
1
1
I
1
I
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
t,
1
1
1
1
1
1
I
1
1
2
1
2
2
2
LET(23S;_67)
_¢___1064
23S1832"[
23519960
_
1
1
1
1
1
1
PRODUCTS
1
1
1
1
1
1
1
1
1
1
1
_ r,_r_
s_ct
to c_angem_'¢_ rx_c_ _r;#_s msem_
SsP_st mm© zsosD_-morrD_L Om_'_<)N
SERIES
60 PARTS
CATALOG
TYPE
12.S000A
A
B C
BREAKDOWN
E F G H iI
SUPPLIES/MAINTENANCE
PRODUCTS
FIG
PART
NO.
12.8006
____t 065
I
NAME AND DESCRIPTION
r
(Note: Assemblies are shown
for component reference
only.)
I
I
(
FUEL SYSTEM PRODUCTS
I
(cont.)
HARNESS. FUF.J_PRO 3_0E WtF SEN-
1
I
soR
23521062
I
SENSOR,
WATER
INFUEL
"NOT SERVICED, USE pART NUMBER
SHOWN
IN PARENTHESES
AND
23518326 P.EPNR KIT.
1 I
I
[
]
I
I
A//kd_',a_n sut_ct_octw,'_ge
w_'_.¢r,c_ce.Anr_s reserved.
_b'1
mo_ © ]_ Dm'eorr Dm.S_CORPORA_ON
12.8000A SUPPLIES/MAIN
I'___IANCE PRODUCTS
J K L M
,
TYPE BREAKDOWN
SERIES
12.8000A
FIG
SUPPLIES/MNNTENANCE
PRODUCTS
PART
NO.
A B IC
60 PARTS
CATALOG
)
NAME AND DESCRIPTION
(Note: Assemblies are shown
for component refeL_=nce
only.)
12.8006
FUEL SYSTEM PRODUCTS
23519237
23519238
23519235
23519236
23519778
23514047
23515125
23516638
23519934
23519o_
23520907
23514049
KIT. FUEL PR0 380E NO HEATW/DIV_HZ_H CAP
_ FUEL PRO 38GE12V HEAT
Q-IROME W/DIV_..m _H CN _
KTE,FUEL PRO 380E 12v HEAT W/DIVE_I=H CAP
KE FUEL PRO 380E 24V HEAT W/DIVm.<l,_r=CAP
lOTFUEL PRO 380 12V/120V HEATW/
DIV_HI ER CAP
PROCESSOR ASSY.,FUEL PRO 380
12V HEAT
PROCESSOR ASSY., FUF_LPRO 380
NO
HEAT
PROCESSOR ASSY.. FUET.PRO 380
24V HEAT
STUD, 13/16"-12, 7/8"-14
PROCESSOR ASSY., FUEL PRO 380
NO HEAT
pROCESSOR ASSY. FUEL PRO 380
12VI120VHEAT
ELEMENT
&GROMMET
ASSy.380
1
1
I
1
1
1
1
1
1
(USEW/23514_IKIT)
23514051
23516794
23516796
23514060
_ WJCA,
P & BOWL0-RINGS
BRACK_-T,FUEL PRO 380 MOUNT
U-CLAMP ASSY., FUEL PRO 380
SPRING, FUEL PRO 380
I
1
2
1
1
1
2
1
23516795
23514048
U-BOLT,
FUELPRO380
COVER,
CLEAR
FUEL
PRO3aO
2
1
2
1
1
23514061
23S16797
23514043
23519943
23519944
COLLAR,FUEL PRO 380
WIRE HARNESS, _
PRO 380
K_, W/CAP& SEAL RiNG
VALVE,CHECK INLET (23519966)
VALVE,CHECK TI_ERM CONTROL IN-
1
1
1
1
1
I
1
1
1
"_
1
I
I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
LET(23519Se7)
23518327
23517427
23517428
23519116
23521060
23S17426
23517425
2351 _
23stg959
_"__
_=;__1068
VALVEASSY. DRNN FUEL PRO 380
HEATER,FUEL/"P,O 3a0 12'4
HEATER.FUEL PRO 38024V
CAP ASSY., DNEH I _H 13/16.-12,
3_25" SEAL ID
HEATER.RJEL pRO 380EE 120V
m_, w_
& W-RAP
HARNESS, FUEL PRO 380 12V..24V
CIRCUIT_=IF_
FUEL PPg)380
TERMtNN., _
SPUCE FUEL pRO
380
CORD, ELEC. HEATER
1
1
1
1
1
1
• NOT SERVICED, USE pART NUMBER
SHOWN IN PARENTHESES AND
23518326 REPNR IQT.
- - ....
12.8000A SUPPLIES/M.MN'IENANCE
PRODUCTS
A;t_
_F,I_
st¢_= to ct_aage
w/#x_"nca_ce.
A_r/_as,'_en_£
98m)@ 1998 DETROITDESELCORFORATION
TYPE BREAKDOWN
SERIES60 PARTSCATALOG
_2.SOOOA
A
SUPPLIES/MAINTENANCE
PRODUCTS
FIG.
PART
NO.
ASSY.
SECT.
NAME
12.8070
AND
DESCRIPTION
HAND CLEANERS
23523182
HAND CLEANER FAST ORANGE
SMOOTH LOTION 15OZ BOTTLE
AR
23523185
HAND CLEANER FAST ORANGE PUMICE LOTION 15OZ BOTTLE
HAND CLEANER _OUNCE LOTION
150Z BOTt3JE
AR
HAND CLEANER FAST ORANGE
SMOOTH LOTION 1GAL BOTTLE
HAND CLEANER FAST ORANGE PUMICE LOTION 1GAL BO'f-i_E
HAND CLEANER TROUNCE LOTION
1GALBOT17.E
AR
LUBRICATING
COMPOUND
BRACKET.BOTTI.
F WALLMOUNT
1Gt_L PUMP
AR
,
_AR
I
23523187
23523183
23523184
23523186
12.8110
23523223
12.8242
THREADLOCK
& SEALER
THREAD
THREADLOCK. MEDIUM STRENGTH
23509535
23509539
(5OML)
THREADLOCK, MEDIUM STHENGTH
(IOML)
TI-iREADLOCK, HIGH STRENGTH (10
ML.)
_IHREADLOCK.HIGH STP_NGTH (50
ML)
THREADLOCK, PENETRATING (10 ML.)
23509542
2350_544
SEALER. THREAD (50 Mr-)
SEALANt. COMPOUND (50 ML.)
AR
_ AR
SEALANT,
RRV "
SEALANT,GASKET EUMtNATOR (SO
ML.)
SEALAN'£,GASKET ELIMINATOR
(50MI-)FOR INSTALLING FRT & REAR
CAMSHAFT CAPS
SEALANt, GASKET EUMINATOR (300
ML.)
I
23509536
23509537
235095_
12.8255
235o954o
23523064
23509541
23509603
"
23509543
23523188
12.8000A
i 1
AR
AR
A_
AR
AR
i
i AR
AR
SEALANT,B.ACR RTV il O7_
_AR
SEALANt. ULTRA
BLUERED
RTVRTV
3 OZ.
SEALANt,
HIGH TEMP
110Z_
iAR
I AR
SUPPLIES/MAINTENANCE
J;.....
PRODUCTS
1j
!.....
I
AUir_o_
s_oje_toct_ngew_r,out_
AI/ngr_ rese,v_
6SP161 9809© 1998 DETROIT DIESEL CORPORATION
SERIES
60 PARTS
RG.
CATALOG
PART
NO.
TYPE BREAKDOWN
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8260
23507855
SUPPLEMEN1;COOLANTADDITNE
1/2 GAL (DD-3000-HG)
_=_
23S078S6
SUPPLEMENt,
COOLANT
ADOmVE
S
GAL(OO-300e-ll)
SUPPLEMENt,
COOt.'U_ADDrnVE
55
GAL.(DD-3000-_5)
_R
SUPPLEMENt. COOLANT ADDITIVE ;
PT.(DD-2000-P)
SUPPLEMEk'_, COOLANTADDnlVE
1/2 GAL (D_G)
SUPPLEM_, COOLANTADDITIVE 5
GAL (DD-2000-11)
SUPPLEMIEN_,COOLANTADDITIVE55
GAL (DD-2QOG-15)
SUPPLEMEfl'C COOLANT,aJo0mVE(1
PT,) (DD-3000-P)
PRECHARGt_ COOLANT(1 GAL.)
CONCENTRATED
AR
PRECHARGED COOLANT(55 GAL.)
CONCENTRATED
PRECHARGED COOLAWf (BULK)
CONCENTRATED
POWERCOOLCOOLANT(BULK)PREBLENDED 5O/50
AR
POWERCOOL COOLANT (55 GAL-)
PRE-BLIENDED50/50
POWER COOL PLUSEXTENDED UFE
COOLANT 55 GAL(OAC)CONCENTRATED
AR
23519395
PWER COOL PLUS EXTENDED UFE
COOLANTBULK(OAC)CONCENTRATED
AR
23519396
POWERCOOLPLUSEXTENDED
UFE
COOLANT 1 GAL (OAC)PF_--B-ENDED
5O/5O
AR
23519397
POWER COOL PLUS EXTENDED UFE
COOLANT 1 GAl. (OAC)GONCENTRATED
AR
23519398
POWER COOL PLUS EXTENDED UFE
55 GAL(OAC)PREBLENDED 50/50
AR
23519399
POWER COOL PLUS EXTENDED LIFE
COOLANT (OAC)PRE-BLENDED 50/50
POWER COOL PLUS EXTENDER FOR
USE W_R
COOL PLUS
POWER COOL PLUS6_00 FOR MAFBNEIOTHERWATERONLYSYSTEMS
POWER COOL PLUS6000 FOR MARINE/OTHER WATERONLYSYSTEMS
23507857
23507858
23507859
23507860
23507861
23507854
23512138
23512139
23512140
23513503
2351891S
23519394
23519400
23522127
23522128
12.8270
23507862
23507863
23507864
23S07867
_t_sl
_
ADDITIVES, SUPPLEMENTAL
COOLANT
_R
AR
AR
AR
AR
A_
AR
AR
CLEANER, COOLANT
SYSTEM
CLEANER, COOLANTSYSllEM I/2
GAL. (DD-2001-HG)
CLEANER, COOL_
S_ I_=M5 G_L_
(DD-200;-11)
CLEANER, COOLANTSYSTEM 55 GAL.
(DD-2001-I 5)
CLEANER. COOLANT SYSTEM (TWIN
PAK) (DD-2015-49)
© ]_s Dm'aorrDIESEL
com_a_oN
12.8000A S UPPLIF,S/MAIN TE_t_qANCE
PRODUCTS
TYPE
BREAKDOWN
SERIES
60
PARTS
CATALOG
i
FIG.
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8280
23507869
ADDITIVES, DIESEL FUEL
ADDmVES.FUEL5 GAL
(D_11)
ADDMVES.FUEL55 GAL.
(DD-2020-15)
ADorers. FUEL'_FT.(DD-1000-P)
ADDITIVES,
FUEL2 GAL
(DD-1000-11)
ADDITIVES,
RJEI.55GAL
(DD-1000-15)
ADDmVES.FUEL(1 FT.){DD-20a)-P)
23507870
23507871
23507872
23507873
23507868
12.8290
23,_15921
23,,_2"r/4
2351940_
AR
AR
AR
AR
AR
KIT, COOLANT ANALYSIS
KE,POWERTRACCOOLANT
ANALYSIS
POI_=R_
COOLANT
TESTSTRIP
(1STF,p)
PowB_TP_c coou_ TES_
2_19401
....
AR
AR
AR
A_
..... POWEBTP._ cooi.tucr TEST
STRIPS (BOTTLED 50 STRIPS)
12.8291
_15823
23517267
23520¢J89
_'_¢_;_1_
23521984
23521983
AR
KIT, OIL ANALYSIS
KIT.POWERTRACLUBEOILANALYSIS
KE, POWERTRAC_
OILEXTRAC_
T1ON
lOT,POINERTRACLUBEOILANALYSISW/TOTAL
BASENUMBER
KIT,POWERTRACLtJBEOILANALYSIS(CANADIAN
ONLY)
K_, POWERTRACOILEXTRACTION
(CANAD_N0_'_
KIT.POWERTRACLUBEOILANN.YSISW_TOTAL
BASENUMBER
12.8293
23516S_2
K_, FUEL ANALYSIS
KE POWERTRACFUELANALYSIS
128300
_7¢j8
PANEL, INSTRUMENT
GAGEPANEL.MECHANICAL
15'CAP*
IIL/tRY 12/24V(7.4005)
G__G_
_ PANELMECHANICAL
30'CAPtL.LARY
12_4V (7.4005)
GAGEPANEL,
INS'mLIMENT
CONTROt.BLANK(7.4O05)
BRACKE'_,
1-HOLEMOUNTINGBLACK
(7.4OO5)
BRACKET+
2-HOLEMOUNTINGRUBBERF.400S)
BRACKE_,
2-HOLEMOUN_NGBLACK
235207b'7
23513680
23519833
23513217
23519834
23519835
12.8000A
AR
AR
AR
AR
AR
AR
AR
AR
AR
BRACKET,
3-HOLEMOUNTING
BLACK
(7A005)
SUPPLIES/MAINTENANCE
....
PRODUCTS
AR
AR
AR
AR
A_
Ail;,,;.,,,alion
st_em1ocPange
w/lhcm
_.
_ d_as_en_d_
¢,S_Sl _m © 1998DEr_orr Dmsra. c_
SERIES
60 PARTS
FIG.
CATALOG
PART
NO.
TYPE
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
BREAKDOWN
A
ASSYo
SECT.
NAME AND DESCRIPTION
12.8310
23519803
GAGE, AMM_-z_R
GAGE, AMMETER 60-0-60 BLACK
AR
ff.4o_s)
___5__0723
23519804
GAGE, AMM_ i_..N60-0-60 CHROME
_.4o15)
GAGE, AMMc:It:H 1G0-0-100 BLACK
_R
&R
(7.4o15)
235207r'r_
23520733
12.8315
23519792
23520732
23519836
GAGE,AMM£-lt=H 100-0-100 CHROME
(7.4015)
GAGE, AMMr-_I=H 150-0-150 W/EXTERNALSHUN'i'CHROME(7.40_5)
GAGE, AIR PRESSURE
GAGE. AIR PRESSURE 150 PSI
SINGLE CHROME (7.4024)
GAGE, AiR PRESSURE 150 PSi
SINGLE BLACK (7.4_4)
KIT,pRESSURE TUBING6' X 1/8" COP*
PER
12.8320
23519774
GAGE, TACHOMETER
GAGE, TACH3000RPM W/O HRMETER
DDEC COMPATIBLEELK (USE SENDEFt2351_19,2351 g820 OR 23519821)
7A060
23519775
GAGE, TACH3(X]ORPMW,t.IRM¢ =,=r_
DDEC COMPATIBLEBLACK(USE
SENDER 2351_19,23519820 OR
23519821)7.4060
GAGE,TACH3000RPM W/HF_t _ i P3_
DOEC COMPAI"IBLECHROME (USE
SENDER 23519619,23519820 OR
2351_1} 7.4060
GAGE, TACH3500RPM 1:2 W/RE'V
COLINi I=HMECH CHROME (7.4060)
GAGE, TACH3,500 RPM 1:2 RATIO ME*
CHAN_U- (7.4060)
GAGE, SPEEDO/rACH MAGNETIC
PICK UP 3.5"1_3/4"-16 (7.4180)
SENDER, SPEEDorrACH HALLEFFECT 7/8"-18 (7.4180)
SENDER, SPEEDO/rACH GENERATOR
7/8"-18 (USE KEY6469745 OR
6469746) (7.4180)
KEY,.152"SPEEDO/TACH_RATOR
KEY,.18T SPEEDO/TACHGENERATOR
23519776
23519777
23520728
23519819
23519820
23519821
6469745
6469748
ssmsl tmoe©]ggsDETRorr
or_
COP.FOP.m'_N
AR
AR
AR
A_
AG
12.8000A SUPPLIES/MAINTENANCE
PRODUCTS
•
TYPE BREAKDOWN
FiG.
SERIES
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
60 PARTS
CATALOG
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8330
GAGE OIL PRESSURE ENGINE
23519790
GAGE OiL PRESSURE 100 PSI MECHANICAL BLACK (7.4070)
GAGE OIL PRESSURE 100 PSI MECHANICAL CHROME (7.4070)
GAGE OIL PRESSURE 150 PSI MECHANICAL BLACK 0'.4O7O)
GAGE OIL PRESSURE 150 PSI ME-
23520731
23519791
23520721
CHANtCAL
CHROME
(7A070)
23520744
GAGE OIL PRESSURE 80 PSI 12V
0-90 OHM CHROME (USE SENDER
23511477_3512594.23512.q79.23513978
)
23519798
GAGE, OILPRESSURE 100 PSI 12V
10-180 OHM BLACK(USE SENDER
2351se26)
[7.4070)
23519799
GAGE, OIL PRESSURE 150 PSi 12V
_0-t80 OHM BLACK(USE SENDER
235_ss2-_ (7Acr.,o)
._
_3Sla-m ........... SE_KO_L-t_
....................
.......
_
23512594
....
.............
8OPSL
1/8-27NP_, DUALSTATION (7.4070)
SENDER,OIL PRESS
80PSI.1/8-27N P'ESTANDARD GROUND
AR
(7.4070)
23512979
SENDER, OIL PRESSURE ELECT 80
PSI FLTING GRD DUAL (7.4070)
SENDER,OIL PRESSURE
80PSI,1/4_-.18NP'_,FLOATING GRD
(7.4070)
SENDER,OIL PRESSURE
100PSL1/B-27NPT STANDARD GRD.
(7.4070)
SENDER,OIL PRESSURE
150PSI,1/B-27NPT, STANDARD GRD
23513978
23519826
23519827
AR
AR
AR
(7.4070)
23519836
KIT, PRESSURE TUBING 6' X 1/8" COPPER
12.8335
GAGE, OIL PRESSURETRANSMISSION
_74_
GAGE, TRA_S PRESSURE 400 PSt
12V CHROME (USE SENDER
23511617, 23513980 OR23513981)
7.4071
AR
23519800
GAGE, TRANS PRESSURE 400 PSI
12V _LACK (USE SENDER 23511617,
23513980 UR 23513..081)7,4071
GAGE, TRANS PRESSURE 400 PSI
MECHANICAL CHROME (7.4071)
GAGE, TRANS PRESSURE 400 PSI
MECHANICAL BLACK (7.4071)
SENDER, I_RANSPRESSURE 400 PSt
1/8"-27 S'i'D GRD (7.4071)
SENDER, TRANS PRESSURE 400PSI
1/8"-27 FLOATINGGRD (7.4071)
SENDER, 1P,ANS PRESSURE 400PSI
1/8"-27 DUAL STATION(7.4071}
_ PRESSURE TUBING 6' X 1/8" COPPER
AR
23520730
23519794
23511617
23513980
23513981
23519836
12.800(0
SUPPLIES/MAINTEaNANCE
AR
AR
AR
AR
AR
AR
PRODUCTS
A// 6d_,+_tio_
_sl
subje_
_©
to c;lange wtthout no_ce. Alt ngi'_
res_v_.
t_o_vE'_or_ DmSELCOP.'_ORmION
SERIES
60 PARTS
CATALOG
TYPE
12.S000A
RG.
PART
NO.
SUPPUES/MAINTENANGE
PRODUCTS
BREAKDOWN
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8340
23520734
23520735
23519787
23519788
23519789
23520736
23520737
23519797
GAGE, OIL TEMPERATURE
GAG_ O,- TEMP 340F 4_ CAPILLARY
MECH CHROME (7.4077)
GAGE,OIL TEMP340F 72" CAPILLARY
MECH CHROME (7.4077)
CAGE. OIL TEMP340F 72" CAPILLARY
MECHANICALBLACK(7.40T/_
GAG;=,OILTEMP340F 96" CAPILLARY
MECHANICALBLACK(7.4077)
GAGE.OIL _EMP 340F 144"CAPILLARY
MECHANICAl.BACK (7.4077)
GAGE, OtL "t_MP 34_F 180" CAPILLARY MB_H CHROME (7.4077)
GAGE.OILTEMP340F360"CAPILLARY MECH CHROME (7.4077)
GAGE,OILTEMP300F,12V(USE
SENDER 23519824 OR 2351_25_
AR
AR
AR
AR
AR
AR
(7.4o77)
23519824
2351o_S
SENDER,OIL TEMP.
300DIEG114-18NP_,STANDARD
GROUND (7.4077)
SENDER,OtL'TEMP,
300DEGI/2-14NP_. STANDARD
AR
AR
GROUND
(7.40T_
23519830
23519829
1_8345
23519779
-
23519780
23519781
23519782
23519783
23519784
23519785
23519786
23520_
23520724
23520725
23520726
23520727
23520738
ADAPTOR. 3i8"-18 NPT MECHANICAL
GAGE
AOAP'TOR, 1_-14 NPT MECHAffiCAL
GAGE
AR
AR
GAGE, WATER
TEMPERATURE
GAGE, WATER TEMP 265F. 18" CAPILLARYMECHANICALBLACK (7.4080)
GAGF- WA'nERTEMP 265F. 30" CAPILLARYMECHANICALBLACK (7.4080)
GAGE. WATER_
265F. 48"CAFn..L_h'MECHAN_CAL BLACK (7.4O8O)
GAGE.WATI_RTEMP265F. 72"CAPILLARYMECHANICALBLACK(7.4080)
GAGE,WATER TEMP265F. 96" CAPILU',RYMECHANCAL BLACK{7.4O8O)
GAGE, WATERTBAP 265F. 144" CARLLARYMECHANICALBLACK (7.4O8O)
GAGE, WATE_R
"Rg_IP2GSF, 180"CARLLARY_=CHAN_,AL BLACK(7.4O8O)
GAGE, WAIER TEMP 265F, 372" CAPILLARYMECHAN.¢.ALBLACK(7.4O8O)
GAGE, WATERTEMP 265F, 18"CAPILLARYMECHANICALCHROME (7.4080)
GAGE, WATER11EMP265F, 30"CAPILLARYM_
_E
(7.4080)
GAGE. WATERTEMP265F. 48" CAPILLARYMECt'U_IC/¢ CHROME (7.408O)
GAGE. WATERTEMP2651.72" CAPILLARYMECHANICALCHROME (7.4080)
GAGE, WATERTEMP 265F, 120"CAPILLARYMECHANICALCHROME
(7.4O8O)
GAGE, WATERTEMP 265F, 144"CAPILLARYMECHANICALCHROME
AFt
AR
AR
AR
AR
_R
AR
AR
AR
/_
AIR
AR
/_q
A.;
(7.4oeo:,
23520701
GAGE. WATERTEMP 265F, 180" CAPILLARYMECHANICALCHROME
AF
(7.4080)
AU_='m.,=_onsz_j_c_
to c_angew'_ho¢_
r,o_ce.AJt,"_
6s_e
_
re=en,ed.
© ]998DzrRorrDI_n. CORPORAnON
12.8000A SUPPLIES/MAIN'IENANCE PRODUCrS
TYPE
FIG.
BREAKDOWN
SERIES
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
60 PARTS
CATALOG
ASSY.
SECT.
NAME AND DESCRIPTION
:_739
GAGE, WATERTEMP26_F, 372" CAPILLARYMECHANICAL CHROME
(7.4080)
12.8345
GAGE, WATER
TEMPERATURE(conL)
23519795
GAGE,WATERTEMP220F 12VUS
23S19796
GAGE, WATERTEMP250F, 12V (USE
S_NDIE_23511301,1303_
OR
9_23)7.4080
GAGE, WATERTEMP250F, 12V
RANGE
(7.4980)
_'__
__=E_0740
(7.4060)
__'___
____I_0742
23519823
23,511303
GAGE,WATERTEMP250F, 32V RESISTER KIT (7.4O80)
SENDER,TEMP.250OEG3_'-18NPT
STANDARDGROUND (7.4_80)
SENDEI_TJ_MP2_EG, 1/2"-14NPT,
STAND_=.D
C-R_D (7.4080)
23S13982
SENDER "t"E]_lP
250OEG 1_-18
.......
......
_LOA_NG
_RDU_b
.............................
_];l-_}_l
............
23513983
23519830
23Sl 9829
12.8350
SENDER,TEMP25_OEG,3_'- 18NP_,
DUAL STATION(7.4080)..........
SENDER, TEMP 250 DEG I/4"-18
DUALSTATIONELTGRD (7.4O80)
ADAPTOR,3/8"-18 NPT MECHANICAL
GAGE
ADAPTOR, 1/'Z'-14 NPT MECHANICAL
GAGE
_:.:
/
..............
GAGE, FUELVOLUME
23519806
23519809
23519807
23519810
23519808
23519811
23519816
23519817
23519818
12.8360
GAGE. FUEL 0-90 OHMCHROME
(USE SENDER 23519816)(7.4086)
GAGE,FUEL 0-90 OHMBLACK(USE
SENDER 23519816)(7.4(_6)
GAGE, FUEL 10-ffi0 OHM CHROME
(USE SENDER 23519817) (7.4086)
GAGE, FUEL 10-180 OHM BLACK(USE
SENDER 23519817)(7.4086)
GAGE, FUEL 240-,33OHM CHROME
(USE SENDER 23519818)(7.40e6)
GAGE, FUEL 240-33 OHMBLACK(USE
SENDER 23519818)(7.4086)
SENDEFLFUEL6-23" .M)JL)STA1BLE
0-90 OHMS (7.4086)
SENDER,FUEL6-23" ADJUSTABLE
10-180 OHMS (7.4086)
SENDER,FUI_ 0-23" _ABLE
240-33 OHmS (7.40e6)
LAMP,
23519828
23519838
23519840
12.8365
INSTRUMENT
PANEL
BULB,TYREC 2W (7.4100)
BULB,TYPET-3 1/4,2.7W WEDGE
BASE (7.4100)
BULB,TYPE3"-31/4, 3.4WWEDGE
BASE(7.4100)
SOCKET, LAMP INSTRUMENT
PANEL
23519839
SOCKET BULB"(-3 114V_EDGEBASE
(7.41o5)
23519841
8g_0_B0
SOCKE'_,BULBTYPE C (7.4105)
SOCKE_, BULBTYPE A
12.S000ASUPPLIES/MAINTENANCE
PRODUCTS
_s't _
tgo_DE'r_orr
Dt_LCO_OP.ATtO_
SERIES
60 PARTS
FIG.
CATALOG
PART
NO.
TYPE BREAKDOWN
12.8000A
SUPPUES/MNNTENANCE
PRODUCTS
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8370
GAGE,HOUR METER
23519812
Mr: rEH, HOUR QUARTZ 9--28V, NON
ILLUMINATED CHROME (7.4118)
AR
i
i
23519813
MI::II::H, HOURQUAR'FZg-#.SV,
NON
ILLUM[NAI_D BLACK (7.4118)
I_= _r.H, HOUR QUARTZ 9-28V, WATERPROOF (7.4118)
klP_fEH, HOUR QUAFRZ )/_NIk_. t _._
9.-28V NON fLLU_MINATED (7.4118)
AR
i
23519814
23519815
12.8375
23519832
AR'
AR i
GAGE, TURBO BOOST
GAC.E. TUI:I_
BOos'r
0-30 PSI
AR_
0'.4_6o)
23519842
235198_
12.8380
23Sl 9801
23S19802
GAGE TURBO BO0_-'T 0-30 PSI
BLACK (7A160)
KIT, PRESSUP, E "[1J_ING 6' X li8" COPPER
AR
Al_
GAGE, voLTMETER
GAGE, VOLTM_I bH 8-16V CHROME
(7.4170)
GAGE, VOLTMz:_t:H 8-16V BLACK
A_
I AR
(7.4170)
12.8385
23519773
23519819
23519820
•
23519821
23520374
6469745
6469746
A./;_nna_on
GAGE, SPEEDOM,- i ER
GAGE, SPEEDO 0-85 MPH PROGRAMABLE W/'_IIP (7.4180)
GAGE, SPEECOtTACH MAGNETIC
PICK UP 3.51.- 3/4"-16 (7.4180)
SENDER. SPEEDOKACH HALL EFFECT 7/8"-18 (7.4180)
SENDEFI, SPEEDOITACH GENB_,ATOR
7/8-18 (7.4180)
AR
SENDER, SPEEDO/TACH GENERATOR
7/8-18 ODO TERM (7.4180)
KEY, .152" SPEEDOKACH GENERA(FOR USE wn'H 2_51982_ OR
2352O374)
KEY, .18T EREEDO/TACH GENERATOR (FOR USE W_H 23519_21 OR
2352O374)
AR
AR
AR
AFt
AR
AR
s,_,L=ctto ct_a_je _Wtho,_r,_ce. AJY
n_sts m_erved.
SSel_ tins © 1998DE'mOrtDrV.SEL
CORPORA'nou
12.8000A S UPPLIES/MAI:N TF..NANCE PRODUCTS
(
CORPORATION
DETROIT
13400
Outer
Drive.
Dli_SIEL
West
/ Detroit,
Michigan
®_1_
48239-4001
DetroitDiesel®andthe spinning._ows are regi_er_ tmdemar_ of DetroitDieselGorpormion.
Printedin U.S.A.
DETROIT
Custom
DIESEL
Parts Catalog
TR/TMD 250 AIR START UNIT
ENGINE SERIES NUMBER:
60
ENGINE MODEL NUMBER:
6063HK33
STEWART & STEVENSON
GENERAL INFORMATION
This customized parts catalog contains
informationspecific to the customer sedal
number. All engine components in this
catalog are divided into major groups of
functionallyrelated parts. A listing of the
groups and their sub-groupsappears under
"GroupNomenclature"of this section,
The data in this publication is based on
information known to Detroit Diesel at the
time of printing.While every care and effort
has been taken to ensure the accuracyof all
The AlphabeticalIndex is particularlyhelpful
superseded or rendered obsolete. Detroit
Diesel reserves the figM to make changes
' tothis catalog at any tirnewithoutnotice.
when only a part name is known and the
groupcan not readilybe determined. Parts
information, engine modifications or
subsequent engineering changes or
enhancementsmay cause certaindata to be
are listed alphabetically by noun name,
followed by a descriptionof the application
of the part and the final grouplocation,
If additional assistance is needed please
contact your authorized Detroit Diesel
serviceoutlet.
Unlike the normal parts catalog this book
does notcontain types. The listingof parts
is separated only by a group identification
(e.g.
1.1000
for
cylinder blocks).
Componentsof major assemblies will follow
the assembly. The order in which parts are
listed is the same as the normal parts
catalog,
IMPORTANT ENGINE INFORMATION
Also included in the last pages of this
catalog is a listing of vadous supplies
requiredto maintainyour engine.
Your engine serial number should be kept
readily available. It can be used to identify
your model as well as ALl. sen,ice parts
including kits, sets, warranty information
and extended coverage available.
CUSTOMER
ASSISTANCE
The satisfaction and goodwill of the
owners of Detroit Diesel engines are of
primary
concern
to Detroit
Diesel
Corporation and its distributor/dealer
organizations.
As the owner of A Detroit Diesel
Product you have a complete network
of over 2,O00 Detroit Diesel service outlets in the U.S. and Canada, plus many
outlets worldwide that are prepared to
meet your parts and service needs:
EASTERNREGION
LongBranch,NewJersey
187 Monmouth Park Highway
WestLongBranch,NJ 07764
Phone:(732)222-1888
Fax:(732)222-3411
WESTERNREGION
Downey, California
10645 Studebaker Road
Downey,CA90241
Phone:(562)929-7016
Fax:(562)864-0502
PACIFICREGION
Australia
47 First Street
BlackRock,Victoria3193
Phone:(61)9589-0484
Fax:(61)9589-6856
SOUTHEASTERN
REGION
Jacksonville,
Florida
5111BowdenRoad
Jacksonville,FL32216
Phone:(904)448-8833
Fax:(904)448-2A.4
A.
CENTRAL REGION
Detroit,Michigan
13400OuterDrive,West
Detroit,MI 48239-4001
Phone:(313)592-5990
Fax:(734)762-1032
CANADIANREGION
London,
Ontario
DetroitDieselofCanadaLtd.
150DufferinAve.,Suite701
London,ONN6A5N6
Phone_
(519)661-0149
Fax:(519)661-0171
LATIN AMERICANREGION
Miami,Florida
2277N.W.14thStreet
Miami,FL33125.0068
Phone:(305)637-1555
Fax:(305)637-1580
SOUTHWESTERNREGION
Dallas,Texas
2711LBJFreeway
Suite1036
Dallas,TX75234
Phone:(972)247-4313
Fax:(972)247-4316
ASIAN REGION
Singapore
No.1 BenoiPlace
Singapore
629923
Phone:(65)865-1911
Fax:(65)861-1618
EUROPE,MIDDLE EAST,
AFRICA(EMA|REGION
TheNetherlands
Ridderpoort
9
P.O.Box4161
2980GDRidderkerk
TheNetherlands
Phone:(31)1804-10208
Fax:(31)1804-62062
MEXICO
DetroitDiesel-Allison
de
Mexico
Av.SantaRosa58
Col. Ampliacion Norte
SanJuanIxtacala,Tlanepantla
C.P.54160,Edodo Mexico
Phone:
(525)333-1802
Fax:(525)333-1870
.
DETROIT
Custom
DIESEL
Parts Catalog
ENGINE DESCRIPTION
TPJTMD250 AIR STARTUNIT
SERIES NUMBER:
60
MODEL NUMBER:
6063HK33
SERIES 60 PARTS CATALOG
1.0000
ENGINE (LESS MAJORASSEMBUES)
1.1000 ....
CYLINDER BLOCK
ALPHABETICAL
5.0000
COOLING SYSTEM
5.1000 ....
FRESH WATER PUMP
1.10(X)A ... AIR BOX DRAINS
1_2000 .... CYLINDER HEAD
5.1000A ... FRESH WATER PUMP COVER
5_000B ... THERMOSTAT
1.2000A . .. ENGINE. LIPI _R BRACKET
5_2000C ... WATER BYPASSTUBE
1.3000 ....
5.3000B ... WATER CONNECTIONS
5.4000A .. _FAN
CRANKSHAFT,,OIL SEALS
AND STAB, 17PRS
INDEX
ALPHABETICAL
INDEX
L]ST
1.3000A ... CRANKSHAFT FRONTCOVER
1.3000B ... VIBRATION DAMPER
5.5000A ... HEAT EXCHANGER OR KEELCOOLING
5.6000A ... RAW WATER PUMP
1.3000C ... CRANKSHAFT PULLEY
1.3000D ... CRANKSHAFT PULLEY BELT
5.7000A ... WATER RLTER
1.4000A... FLYWHEEL
6.0000
EXHAUST SYSTEM
1.5000A ... FLYWHEEL HOUSING
6.1000A ... EXHAUST MANIFOLD
AND/OR CONNECTIONS
1.5000B ... FLYWHEEL HOUSING ADAPTOR
1.6000 .... CONNECTING ROD AND PISTON
1.7000 .... CAMSHAFT AND GEARTRAIN
6_000A .,. EXHAUST MUFFLER
AND/OR CONNECTIONS
6.60001 ...
1.7000A .,. BALANCE WEIGHT COVER
1.7000B .,. ACCESSORY DRIVE
1.8000 ....
7.0000
VALVEAND INJECTOROPERATING
MECHANISM
7.3000A ... STARTING MOTOR
7.4000B ... TACHOM¢.I _R DRIVE
1.SC00A ... ROCKER COVER
2-0000
7.70COB... THRO3TLE ANDGEAR CONTROL
FUEL SYSTEM
SYSTEM ELECTRONIC
7.7000C ... CRT AND LCD DISPLAY
SYSTEM ELECTRONIC
2.1000A ... FUEL INJECTOR
2.1000B ... INJECTOR CONTROLS ELECTRONIC
2-2000 .... FUEL PUMP
2.3000A ... FUEL RLTER AND STRAINER
2.4000A ... ALTERNATE FUEL SYSTEM
2-5000A . .. FUEL LINES AND FUEL COOLER
ELECTRICAL
INSTRUMENTS
7.1000A ... BATTERY CHARGING GENERATOR
7.8000C ... SPARK PLUG,IGNITION COIL,
WIRING HARNESS
8.0000
POWER TAKE-OFF
8.1000A ... POWER TAKE-OFF ASSY.
2.7000A...
2.9000 .... INJECTOR CONTROLS
9.0000
2.g000A ... THROTfLE CONTROLS
11.0000
3.0000
AIR SYSTEM
3.1000A ... AIR CLEANER AND/ORADAPTOR
3.3000A ... AIR INLET HOUSING
3.3000C ... AIR INTAKE MANIFOLD
TRANSMISSION
ANDPROPULSION
9.1000A ... MARINE GEAR
ENGINE
MOUNTING
_IJ000A .. ENGINE MOUNTING BASE
12.0000
MISCELLANEOUS
12.4000A .. AIR COMPRESSOR
12_5000A.. HYDRAULIC PUMP
3.4000 .... BLOWER AND DRIVE
3.4000A ... BLOWER DRIVE SHAFT
12_6000S.. AIR STARTER
12.6000C .. COLD WEATHERSTARTING AIR KIT
3.5000A ... TURBOCHARGER
17_7000A.. APPEARANCE PACKAGEPARTS
3.7000 ....
12.8000A .. SUPPLIES/MAINTENANCE PRODUCTS
4°0000
INTERCOOLER/AFTERCOOLER
LUBRICATING SYSTEM
4.1000A ... OIL PUMP
4.1000B...
1_8OOOB
.. FABRICATION MATERIAL
12.81X)0C.. SERVICE KITSAND S_J_
OIL DISTRIBUTION SYSTEM
4.1000C ... OIL PRESSURE REGULATOR
4.2000A ... OIL FILTER
4.3000A ... OIL FILTER LINES
4.40(X)A ... OILCOOLER
4.5000A . .. OIL FILLER
4.6000A ... DIPSTICK
4.7000A . .. OIL PAN
4.8000A ... VENTILATING SYSTEM
6SP161_
© 1998DETROITDIESELCORPORATION
1-- ]
SERIES 60 PARTS CATALOG
ALPHABETICAL INDEX
PARTNAME
GROUP
NO.
A
PART
NAME
GROUP
NO.
BO_,E_USTM_FOLD
TOHEAD
7. 7460B
BOLT,_
ACTUATORASSY.,NATURALGAS
2. 9395A
BOOTAND SPRINGIGI_RON
ADAPTOR_
1. 3281C
ACTUATORASSEMBLY,GEAR
POWERTAKE OFF
ADAPTOR DIPSTICK
ADAPTOR FLYWHEELHOUSING
4. 6030A
1. 5130B
ADAPTOR FUEL PUMP DRIVE
2.2260
COVER
1. 8460A
7. 0,,_IoC
C-.-.-.-.-.-.-.-.-AS
VALVE_
2. 4145A
BRACI<L_IGNITIONC,G¢
7. 8705C
BRACi_T OIL FUI _R l"t_E CLAMp
BRACI_"I AC'[UATOR& _
AC'I1JATOR
MOLIN/1NG
12.5020A
ADAPTOR OIL COOLER
4. 4110A
AFt_
4. 2291A
BOATBUILDERr,qB_CE
ADAPTOR TACHOME_P.HDRIVECABLE
7. 4420B
ADAPTOR TACHOMt- iI::HMOUNTING
12.8325A
ADAPTORWATERPUMPDRIVE
3.7005
ADDITIVE CURING ('rHREADLOCK& RTV)
12.8252A
4. 5004A
BODy
ADAPTOR HYDRAUUC PUMP
ADAPTOR OIL RL'I'ER COVER
6.10_A
2. _.
2. 1780B
MOUNTING
MODULE
BP.ACK_ B_F.A1HEREXTIE_NSION
PIPE
ELECTRONICDISIRIBUTORUMT
12.4010A
2.15148
4. 8183A
2. _5_
_"_E¢_
BRACK_ ENGINEIJPz¢:H-- RF..N:I
1._
BRACK_ BqG_IE La-Itd._-FRONT
1. 2070A
FANB_T _
5. 4342A
ASSY
ADDITIVES,DIESEL FUEL
12
ADDITIVES, SUPPLEMENTALCOOLANT
12.8260A
BRACK_ RIg. FILI-'_IMOUNIING
3. 3801C
BRACKL_CIENEPATORADJUSTING
S'IRN=
7. 1582A
AIRSTARTER
ASSY.
12.6080B
BRAC;<rl (3_EPA_
7. 1565A
NR S'_:tAINERAND LUBRICATIONASSY.,
AIR STARTER
OILC(XX.ERHOUSINGSUPPORT
4. 4100A
12.6120B
_
(]L PUMPSCREI_I Sl.,I:PERT
4. 1540B
APPEARANCEPACKAGEPARTS- SECTION1
12.7001A
_
Pe_B_SEGEARMOUNTING
9. 1011A
APPEARANCEPACKAGEPARTS- SECTION3
12.7003A
BP,ACKL_SNE_MODULEMOUN_NG
2. _
APPEARANCEPACKAGEPARTS- SECTION5
12.7005A
BRACKL=IST/_G
IVIU
IUP_SI.IPI_¢_
7. 3007A
ARM ASS_.,EXHAUSTVALVEROCKER
1. 8060
BRACKB WATER_
MOUNTING
5. luuu_
ARM ASSY-,INJECTOR ROCKER
1. 8060
_
FAN_
ARM ASSY.,INTAKEVALVEROCKER
1. 8075
_
BUSH_
INJECTORROCIKZ_ARM
OILPUMPBODY
A/R iNTAKEMANIFOLD
M(X,W]ING
IDLERR3.I.EY SUPPORT
2. =?__
_'_'_
5. 4348A
1. 8110
4. 1050A
B
BALLAND SEATASS_.,INJEu_uR _
BEAF_NG.
ACCESS(_
ARM
DF4VE
1. _Rr___
C
1. _---,.._,_
CAMSHAFTASS_
1.7001
BEA_
AIR COMPRESSORDRNE SHAFT
12.4048A
CAR_
_
CAMSHAFT
1.7040
CAR,P._,AblSI.tAFT
_
1.7042
_
CLLITCHPiI.OT
1. 404_A
CAROILF4.LER
4. 5010A
BEARING,FANSPB4D__
_.
FRESHWATERPUMP
5. 4111A
3. r,_u
CAPLUGR/C $60
CHNN, O¢ Rt.LB_C,AP
1. 8043A
4._
BEARING,FLE_ PUMP
2._n
_
3. 1280A
BEAF_NG,II].ER GEAR
1.7225
CLAM_,BREA'rHER
"RJ_E
4. @-=k,_
_
1._42
_
INJECI"OR
2. 1270A
1. =_;_,i,-,
_
_,TER _
7. 157"--J_
_
PISTONPIN.
BELT,_
PUU.EYDRIVE
BELT,,
C_E]_ATOR DRIVE
_
FANH[C-;HLOW,AI_ _
MAINBEARING
AIR IM..ETPIPEI-IOS_
INLETPIOSE
COOLN_ S'_ Jt:_l
1.3110
5. 1,3E6A
1_)R_70A
CU_,_
1. 756_
MOUNTED
B.CX2_ _
5. 4010A
1.1001
CLI_,AIR COMPI_S_
WAI'B:I_
CL_,BREA'R-_:_"II.IE_
12.40g_
4.8040#,
_
2. 525(_
CUR,COLD PLATETO _
2. 5121A
3. 7190
_
SYS'f'B__
BOO_,FRESHWA'IERPUMP
HOSE
CYLINDERI'F-ADINLET
2. 5180A
BOD_,OILPRESSUP_F_=GLe_TORAI_) RI=111=1: 4, 1680C
CI,._,DIFSTIC_
4. 6040A
BOOY,OIL _
4. 1040A
CU_,FLEXIBLEHOSE
12.8554_
CAp
1.7046
CI.R,FUELDP,A_
2. _'_A
MAINBEAR_G CAp
1.3140
CI..R,O_ RL.1.B:t
LINE
4. 3045A
BOLT,CAMSI-IAFT_
BOLT,_
An_d_ma_ms_t _omatte wmzt_r,_ce. A_',_,_ _
_s_
_
© l_es wrRorr D_.¢O_N
1-3
ALPHABETICAL
INDEX
PART
NAME
SERIES 60 PARTS CATALOG
GROUP
NO.
PART
NAME
GROUP
NO.
CUP,STRAINER TO FUELPUMP
CUP,TURBOCHARGER OIL RETURN TUBE
2. 5070A
3. 5507A
DRIVEGEAR,AIR COMPRESSOR DRIVEASSY.
12AO72A
CUP,TURBOCHARGEROIL SUPPLYTUBE
3. 5S0_
CUP,WATER BYPASSTUBE
5. 2190C
_W,
CUP,WATER PUMPTO OIL COOLERTUBE
5. 34_B
ELEMEN'E,FUEL FILTER
2. 3320A
CLUTCH ASSY.,FAN
5. 4112A
ELEMEN'_,FUEL STRAINER
2. 3010A
COIL IGNITION
7. 8710C
ELEMENT,OIL FILTER
4. 2250A
COLDWEATHER STARTINGAIDKIT
COMPRESSOR ASSY,,AIR
12.6301C
12.4001A
ELEMENt, WATERFILTER
5. 7020A
CONNECTING RODASS'/.
CONNECTION, FLEXIBLEEXHAUST
6001
6. 2095A
E
TUR_CHARGER AIR INLET
1
3. 1259A
F
CONNECTOR, DEUTCH
2. 1850B
FILTERASSY.,WATER
5. 7001A
CONNECTOR, PERIPHERAL
2. 1580B
CORE, OIL COOLERENGINE
4. 4001A
RLTER UNI_,BREATHER
FFR'iNGS, FLEYJSLEHOSE END
4. 8060A
12.8552B
COUPUNG, AIR COMPRESSORDRIVE
12AOSOA
FLYWHEELASSY
1. 4001A
COUPLING,FUELPUMPDRIVE
2. 2230
FORK,FUELPUMP COUPLING
2. 2220
COUPLING, HYDRAUUCPUMP DRIVE
12.50i0A
COUPLING, WATERPUMP DRIVE
3. 7025
FUEL SYSTEMPRODUCTS
FUEL/AIRSEPARATOR
12.8006A
2. 3305A
COVERAS SY-,ACCESSORyDRIVEACOUSTICAL 1_7540A
.........
.cov
cousT.:u_
.................
........................................
COVER ASSY,,ROCKER........
1. 84506.
GAGE,AIR PRESSURE
12.8315A
COVER, ACOUSTICAL
1.7530A
GAGE AMM_-IER
12.8310A
COVER, AIR COMPRESSORDRtVEADAPTOR
12.4032A
GAGE FUEl.PRESSURE
12.8355A
COVER, BALANCEWEIGHT
1. 7470A
GAGE FUELVOLUME
12.8350A
COVER, CAMSHAFTBEARINGCAP
1.7037
GAGE HOUR METER
12.8370A
COVER, ENGINE FRONTACCESSORYDRIVE
1. 3191A
GAGE OIl.PRESSURE-ENGINE
12.8330A
COVER, FRESH WATERPUMP BODY
5. 1031
GAGE OILPRESSURE - "TRANSMISSION
12.8335A
COVER, FUEL FILTER
2. 3390A
GAGE OILTEMPERATURE
12.8340A
COVER, FUEL STRAINER
2. 3080A
GAGE, SPEEDOMETER
12.8385A
COVER, GEAR GASE
1. 3158A
GAGE,TACHOMETER
12.8320A
COVER, INJECTORHARNESS
2. 1702B
GAGE,TURBO BOOST
12.8375A
COVER, OIL RLLER HOLE
4. 5070A
GAGE,VOLTMETER
12.8380A
COVER, OIL PuMP
4. 1220A
GAGE,WATERTEMPERATURE
12.8345A
COVER,TACHOMETERDRIVE
COVER,THERMOSTATHOUSING
7. 4445B
5.2120B
GASKET_ CYLINDER HEAD OVERHAUL
GASKETKIT,ENGINE OVERHAUL
1. 2002
1.1002
COVER,WATER RLTER
5. 7034A
GASKEt,ADAPTORTO OIL COOLERHOUSING
4. 4112A
COVER, WATERPUMP
5. 1235A
GASKE'_,AIR COMPRESSOR DRIVEHOUSING
12A039A
COVER, WATER_
12.4005A
3. 7030
GASKEt,_R cOMPRESSOR MOUNTING.
COVER,FUEL PUMP
INLET
2. 2030
GASKEt, AIR INTAKEMANIFOLD
3. 3803C
CRANKSHAFTASSY.
1. 3001
GASKET,AIR STARTERMOUNTING
12.6085B
CYLINDER KIT
1. 6182
GASKET,BALANCEWEIGHT COVER
1. 7480A
GASKET,BREATHERSHELLCOVER
4. 8057A
GAs_-I: CYLINDER HEAD COMPRESSION
1. 2010
D
DAMPER, VIBRATION
1. 3210B
GASKET,DIPS'lICK
4. 6010A
DIPSTICK
4. 6001A
GASI_="_,,
ENGINE FRONT ACCESSORYDRIVE
1.3192A
DISC, FLYWHEELFLEXIBLECOUPUNG
1.4075A
_
6. 1010A
DRIVEASSY.,ACCESSORY
1. 7600B
GASKEt, FRESH WATERPUMP
3. 7185
DRIVEASSY.,AIR COMPRESSOR
12.4030A
GASKI---T,
FRESH WATERPUMP BODYCOVER
3. 7195
DRIVEASSY.,FUEL PUMP
2, 2240
GASKE'I_,
FUEL PUMP COVER
2. 2040
] --4
EXHAUSTMANIFOLD
6SP161_
© 1998DETROIT
DIESELCORPORATION
SERIES
60 PARTS CATALOG
ALPHABETICAL
PARTNAME
GROUP
NO.
GASKE'[ FUELPUMP TO ENGINEOR DRIVE
ASSEMBLY
PARTNAME
INDEX
GROUP
NO.
HEADASS_.,CY[.ff,,JDB:[
1. 2001
2. 2007
HEATSHIELD,EXHAUSTMANIFOLD
6. 117"1A
GASKET,FUELPUMp VALVEPLUG
2.2180
HOSE ASSY_AIRVENTpj ¢=_=r.s_
_
2. 5530A
GASK_-"_,
HOUSINGADAPTOR
3. 7012
HOSEASSY.,PRO-O,,E_ IM.ET
2. 5510A
GASKE'E,HYDRAUUC PUMP
12.5005A
HOSE _,
2.
GASKEI OIL COOLER ADAPTORTO BLOCK
GASKE-I OILCOOLERCORE-INNER
4. 4115A.
4. 4030A
HOS_ ASSY..AIRBAI.ANCELINE
_
HUMPADAPTORTO INT TUBE
2._
2. 41gP_A
GASKEI OIL COOLERCORE-OUTER
4. 4040A
HOSE,COLD PLATETO FL,-ER
2. 5116A
GASKL='IOILCOOLER HOUSING
4. 4055A
HOSE,COLD PLATETO FUEL_
2. 5117A
GASKEt OILRI I FR HOLECOVER
4. 5GBOA
HC_E, FB,
J-'B:_TO _
4. 5007A
HOSE,_
4._
_
4. 1730C
HOSE,_
GASKEI OiL PUMP INLETPIPE
4. 1520B
HOSE,FUELPUMP OUTLErTO COLDPLATE
2. 5115A
GA_
2. 5110A
OILRLLER TUBEADAPTOR
GASKE'I OIL PAN-ro BLOCK
OiL PRESSUREREGULATORBODY
OIL PUMP OU11.ETPIPE
PRO--CHB<OUll.E-I"
HEAD
2. 5160A
F (BULK)
_
12.8550B
DP_IN
2. 5215A
PUMP NET
2-
4. 1590B
_
GASI'_¢'IROCKERCOVER
1. 8455A
I..IOS__
GASK_ STARTINGMOTOR
7. 3004A
HOSE,_
GASKE] TACHOMETERDRIVECOVER
TURBOCHARGEREXHAUSTINLET
CONNECTION
7. 4447B
HOSE,OIL RLTER
3. 5307A
_
GASKE1 TURBOCHARGEROiL RETURNTUBE
3. 5506A
HOSE,WATER_
GASKE1 WA'I_ERPUMP COVER
5. 1236A
HOS_ WATERRLTEROUTLET
5. 7100A
GAUGE AIR PRESSURE METRIC
12.6140B
_
5, 3401B
GEAR ASSY.,ADJUSTABLECAMSHAFTIDLER
1.7221
I-IOL,E_GASSY.,_
1.5001A
GEAR ASSY.,HYDRAUUCMARINE
9. 1001A
_
ASS_, GEARCASE
1.3156A,
GEAR ASSY.,IDLER
1.7220
_
_
GEAR, ACCESSORYDRIVESHAFT
1. 7642B
_
AIR COM_
GEAR, CAMSHAFTAND BALANCESHAFT
1.7200
HOUS_G, FANDRNE SPINDLE
5. 4103A
GEAR CRANKSHAFTTIMING
1.3145
HOUSING,OILCOOLER-ENGINE
4. 4050A
GEAR FLYWHEELRING
1. 4010A
HOUSING.OILI_IANSI=ERCOOLER-RLTER
AI3APT(:_
4. 4053A
GEAR FRESH WRIP_.HPUMP DRWE
5. 1190
HO___
3. 50(_A
GEAR FUELPUMP DRIVE
2. 2087
_
GEAR FUELPUMP DRIVEN
2. 2088
HIJB,AIR _
GEAR HYDRAULICPUMPDRNE
12.5030A
_
GEAR IDLER
1.7222
HUB,_
GEAR OILPUMP DRIVE
4. 1090A
HUB,FLYWHFR _
GENERATORASSY.
7. 1001A
_
GOVERNOR K_, AIR COMPRESSOR
GUIDE, DIPSTICK
12.43GSA
4. 60_0A
HUB,IDLERGEARBEARING
GUIDE, EXHAUSTVALVE
1. 8320
H
I..IAND_
_
_PUMP
OEffLL=TTO_
St.IFPLY
2. __
_r,,'37
_JgA._
VENT
7.1GIP..A
8. lgg0A
WATERBYPASSTLIBE
5. 2165C
B'C-EI"
5. 7090A
WA']'B:IPUMPTO OILC(:X3t.E]:I
DRIVE
1.7627B
DRIVE
ADJUSTABLE
_
12.40_
GEAR
1. 7255
12.4040A
_GEAR
1.7206
PUU..EY
1. 3310C
COIJFUNG
1. _!t3_3A
IDUE_GEAR
1. "/250
1, 7228
|
IDLERASS_, GBqB_ATORDFa'VEl_t_T
IDI.B_ PLILLEYFANt=_ T WffH _
.a,P_
7. lg05A
5, 4325A
ASSY,_
12.807G_
1.8050
IMP_ t P_ F[_SH WA'rB:IPUMP
INJECI'ORASSY
3. {_,_b
2. 1001A
HARNESSGROUNDIGNmON
7. 8720C
_SE_:_ B0-1N.ISTVALVE
1.8330
_,
2. 16_0B
INSTALLATION
I'_'_,WATERRLTER
5. 7010A
2. 1700B
INSULA'RON_
INSULATORASS_,_
3. 5535A
1. 3311C
2-17208
INTERCOOt.B_ASSY
ECM BoA'r BUEDERIN'TEF£4d3E
M(X_LE
HARt_SS, _
_
DISTIIBJTORUteTTO
ENGINESENSORSTO DISCONIW'cCT
6SP161 gs_ © 1998DETROITDIESEl.CORPORATION
_
PULLEY
3.7001
1-5
ALPHABETICAL
INDEX
PARTNAME
SERIES60 PARTSCATALOG
GROUPNO.
ISOLATOR, ROCKER COVER BOLT
GROUPNO.
1. 8461A
j
JACOBS 8RAKE CYLINDER
PARTNAME
1. 8070
O
OIL, ENGINE _CATING
OVEP,HAUL I_, FUEL PUMP
12.8(_Z5A
2.2OO4
OVERHAUL 10T.OIL PUMP
4. IO(_A
K
p
KIT ENG]hE OVERPLe__
1. 1006
PAIN'S,ENGINE TOUCH-UP
12.8001A
KIT FRESH WATER PUMP
3. 7180
PAN, OIL
4. 700"1A
I_T WASTEGATE ACTUATOR
3. 5004A
PANEL, CONTROL
7. 7470B
1<3_+
CONP_C/]P_
PANEL INSTRUMENT
t2.8300A
KIT,COOLAN_ ANALYSIS
ROD BEARING AND GASKET
1_
PiN, AL_NM_NT
2.2012
KE COOLANT _
2. 16-K_
RN, RSTON
1.6140
KE CYIJNDER UNER AND SEALS
1.6181
PIPE ASSY, BREA_
4. 8001A
t<3"[,
_
1. 4074A
PtF_, OIL PUMP INLET
4. 151(_
t_, EPROM S'rA_[rTl_l
2. t50_3
PIPE, OIL PUMP OU'il.ET
4. 1581_
K_, _
12_(_oA
PISTON 1<31"
1. 6110
12._3A
PLATE ASSY., ELECTRONIC DISTRIBUTOR UNIT
SENSOR
ADAPTATION
MAINTENANCE-FUEL/OL
FUEL ANALYSIS
K_, GENERATOR BRA_
........
TENSIONER & BF_LTS
.... i
1.6095
7. 1940A
COLD
2. 1520B
++J.+mr+. + ++m.+rz+++c,m+mD
....I:,,,,,u.....................
OK. ANALYSTS
12.8291A
PLUG SPARK
7. 8700C
I_, OIL RLL,'DRAIN
4. 5090A
PLUG, BREATI-ER HOLE
4. 8043A
I_, _
2. 1755B
PLUG, OIL COOLER BYPASSVALVE
4. 4160A
123390A
PLUC%OIL PAN OP,AIN
4. 7080A
3. 5008A
POW]E_ TAW:_FF _
B. 1001A
12.8715C
PROM AND CARRIER ASS_., ELE_
CONTROL
2. 1505B
CONNECTOR AND TERMINAL
K_,_
TURBOCHARGER REPAIR
KITS, SERVICE (ALL)
L
_
AND HUB ASSY, FAN
ACCESSORY DRIVE
5. 4015+4
1+7605B
LAMP,INSTRUMEN_ PANEL
12.8360A
PLIL,LE_,C3RANKSHAFT
1. 3280C
LCD DISPLAYASSEMBLY
7. 7701C
_
GENEP,ATOR
7. 1500A
LEVERCONTROL, GEAR AND THROTIrLE
7. 7430B
PUMP ASSY., FRESH WATER
5. 1001
LOCK, E)tHAUST VALVESPRING
1. 8370
PUMP ASS'Y+,FUEL
2.
1. 7650B
PUMP ASSY., HYDRAUUC
12.5001A
12.8110A
PUMP ASSY, OIL
4+ 1001A
_NG,
ACCESSORY DP_VE
LUBRCATING COMPOUND THREAD
M
_,
E_MST
R
6. ioola
_
MINDEP_ ENGINF-_iP.:H
2. 18_0_
REGULATOR ASSET
MIX]P,,_IUN_
2. 4137A
P_TOR,
MODULE ASSY., ELECTRON_ CONTROL (ECM)
2+ 1501B
MODULE SPARK INTERF+_CE
7+ 8725C
REPAIR K_, CONNECTOR AND SEAL HARNESS
2. 1758_
MODULE, BOAT BUILDER _ACE
2. 1512B
REPAIR KE HARNESS "I_P,MINAL
2. 1757B
MODULE. CONTROL STATION INTERFACE
7. 745013
RETA_
4. 8065A
MODULE, ELECTRONIC DISTRIBUTOR UMT (EDU)
2.151013
F_TAINER, CAMSHAFT AND ACCESSORY GEAR
1.7240
MODULE, ENGINE ROOM INTERFACE
7. 7440B
RETAINE_, CLUTCH PILOT BEARING
1. 4045A
IdODLILE, _
NOISE i_
MOTOR ASSY., STAR"_NG
2. 1655_,
7. 3001A
RETAINER, FRESH WATER PUMP BEAF_NGAND
SEAL
5+ 1071
MOUNTING, ENGINE FRONT SUPPORT ELASTIC
11.1072A
RETAII\ES& PISTON PIN
1,6150
]. _6
I<_, FI_SH
WA'I_R pLIMP
5.10_
GAS
2. 4136A
OIL PRESSURE
4+ 1670C
_+:1t_;:_,VALVE OIL PRESSUP,E
4.1671C
_:_F-A3"HE_PAD
AIl _fot_tion
sub_ct to _nge
ll¢#nol,'t n_tlc_.
6SP_61
9809 © 1998 DETROIT
DIESEL
A/l _
++as_+
CORPORATION
SERIES 60 PARTS CATALOG
PARTNAME
ALPHABETICAL
GROUP
NO.
PART
NAME
INDEX
GROUP
NO.
RING SET,PISTON
1. 6115
SHIELDING,FLEXIBLEHOSE
2. 5255A
RING, INJECTOR SEAL
2- 1040A
SHIM,OILPUMP
4. 1030A
RING,PISTONCOMPRESSION
1.6120
SLEEVE,
CRANKSHAFT
OILSEAL
1.3167A
RING, PISTON OIL CONTROL
1,6130
SLEEVE,CRANKSHAFTREAROIL SEAL
1. 3066
ROD, PUSH
1. 8180
_
12-8365A
ROTATOR,VAL'VE
1.8365
SPACER,GENERATORADJUSTINGSTRAP
7.1581A
SPACER,|DI..B:IGEAR BEARING
1. 7226
SPACB_
PULLEY
5.401BA
S
LAMPINSTRUMENTpANEL
SCREW, ROCKER ARMADJUSTING
SEAl. ACCESSORY DRIVE OIL
1. 8135
1. 7660B
SPACER,ROCKERSHAFT
SPACER,VIBRATIONDAMPER
1. 8173
1. 3275B
SEAl. BALANCEWEIGHT COVEROIL
1. 7472A
SPINDLEASSY.,FANDRIVE
5. 410P.A
SEAl. CAMSHAFT THRUST PLATE
1. 7075
SPINDLE,CRANKSHAFTPULLEY
1. 3283C
SEAl. CRANKSHAFT OIL
1. 5004A
SPRING,E)0-1AUSTVALVE
1. 8340
SEAl. CRANKSHAFTOIL FRONT
1.3166A
SPRING,OILCOOLER BYPASSVALVE
4. 4150A
SEAl. CRANKSHAFT OIL-FRONT
1.3040
SPRING,OIL RLTER BYPASSVALVE
4. 2486A
SEAl. CRANKSHAFT OIL-REAR
1. 3060
SPRING,OIL PRESSUREREGULATOR
4. 1690C
SEAL, C'/UNDER LINER
1.6190
STAND,ENGINE SHIPPING
11.1045A
SEAL, FANSPINDLE
5. 4160A
STRAINERASSY.,SPIN-ON FUEL
SEAL, FRESH WATERPUMP
3. 7210
S'_
AIR_
SEAl., FUEL PUMP OIL
2.2070
_
OILFg_F:_TLIBE
SEAL, THERMOSTAT
5. 2060B
S'IP,AR,_TOR
SEALANT,RTV
12-8255A
S'IRARWIREASS_ TO GENERA'I'OR
_
7. 1633A
SEAT,EXFLaJJST
VALVE SFRING
1.8360
SnJD, EXHNJST_
6.1(_2A
SEAT,OIL PRESSURE REGULATOR
4. 1701C
SUPPORTASS_, FANBELT_
PULLEY
5. 4347A
SENSOR ASSY.,KNOCK
2. 1648B
SUP,PORT,BELTTENSIONER BRACKET
7. 1g3,.SA
SENSOR, AIR INTAKE
3. 3810C
SUPPORT,ENGINE FRONT
11.1070A
SENSOR, AIR PRESSURE
2. 1650B
SUP_T,
ENGINE REAR
11.1100A
SENSOR, AIR TEMPERATURE
2. 1647B
SUPPOR'/;FANMOUNTING
5. 4025A
SENSOR, COOLANT LEVEL
2. 1665B
SUPPORT,GENERATORBRACKET
7. 1596A
SENSOR, MAG. CRANKSHAFT
2. 1620B
SUPPOR'_,OILFILTERMOUNTING,
4. 2470A
SENSOR, MAG. IDLER
SENSOR, OIL OR FUEL PRESSURE
2. 161013
2. 1600B
SWITCH,EMERGENCYBACKUP
7. 7465B
SB,B_ OL R.__ORCOQ_ _,_TU_
2-I=0S
SENSOR, OXYC-.
-_ N
-.
2. 1671B
TENSIONERASSY.,GENERATORDR!V£
7. 1900A
SEPARATOR,FUEL WATER
2. 35g0A
TENSIONER,BELT
5. 434OA
SERVICE KIT,INJECTOR
2. 1002A
TERMINALRING TYPE
1.8810
SETS, SERVICE (ALL)
12.8720C
THERMOSTATASSY.
5. 2050B
SHAFT AND GEAR ASSY.,OILPUMP DRIVE
SHAFT AND GEAR ASSY.,OILPUMP DRIVEN
4. 1065A
4. 1075A
THERMOSTAT,LUBE OIL
THREADLOCK& SEALER
4. 2288A
12-8242A
SHAFT ASSY.,FRESH WATERPUMP
5.1050
TRIP RECORDERANALYSISCONTROL _
2. l!_0B
SHAFT ASSY.,ROCKER
1. 8160
TUBE AIRINTAKE
2. 4171A
SHAFT,ACCESSORY DRIVE
1. 7640B
TUBEEXTENSION(NATURALGAS ENGINE)
1. 8453A
SHAFT,AIR COMPRESSOR DRIVE
12.4047A
TUBE GASGOVERNOR INLET
2. 4170A
SHAF'_,TACHOMETERDRIVE
7. 4435B
TUBE,AIRCOMPRESSOR BOOSTER
12-4375A
SHELL, BREATHER
4. 8055A
TUBE,AIRCOMPRESSOR LUBE OILDRAIN
12.4070A
SHELL, CONNECTING ROD BEARING
1.6100
TUBE,AIRCOMPRESSOR LUBE OILSUPPLY
12.4065A
SHELL, CRANKSHAFTMAIN BEARING
1. 3090
TUBE,AIRCOMPRESSORWAIP-_ INLET
12.4085A
TUBE,AIRCOMPRESSORWAI _ OUTLET
12-4090A
TUSE,FUELPUMP TO CYLINDERHEAD
2. 5101A
SHII=113ASSY.,ELECTRONIC UNIT DISTRIBUTOR
HEAT
A/tk_m-,at_s_)_c__ ctamge
u_;¢_r_ce. A_r,9_stasensd
SS_Sl m © z_s DE'rRorrD_.SE_.CORPOP._ON
2. 1525B
2. 3006A
ON COMPRESSOR 12.4300A
4. 5(_0A
ADJUSTING
7. 1580A
TO TIJRBCOrlARG_
T
1--7
ALPHABETICAL
INDEX
PART NAME
SERIES
GROUP NO.
TUBE, GENERATOROIL DRAtN
TUBE, GENERATOROIL SUPPLY
7.1003A
7. 1004A
TUBE, INTAKEADAPTOR
2. 9397A
TUBE, JUNCTION BLOCKTO COLD PLATE
2. 5167A
TUBE, JUNCTION BLOCKTO CYLINDERHEAD
2. 5175A
TUBE, O|L FILLER
4. 5001A
TUBE, OiL FILTERINLET
4. 3001A
TUBE, OIL RLTER OUTLL=T
4. 3020#.
TUBE, STRAINERTO FUEL PUMP
2. 5050A
TUBE. TURBOCHPLRGEROIL RETURN
3. 5505A
TUBE, TURBOCHARGEROILSUPPLY
3. 5500A
TUBE, WATERBYPASS
5. 2160C
TUBE, WATERPUMP TO OILCOOLER
TURBOCHARGER
5. 34008
3.5001A
] -- 8
PART NAME
60 PARTS CATALOG
GROUP NO.
V
VALVEASSY..FUELPUMP
2. 2130
VALVE,EXHAUST
1, 8310
VALVE,FUEL DRAINCHECK
2. 5209A
VALVE,FUELSUPPLYCHECK
2. 5006A
VALVE,FUEL SYSTEMSHUTOFF
2. 5260A
VALVE,INTAKE
1. 8315
VALVE,OILCONTROL('rHERMATIC)
4. 4066A
VALVE,OILCOOLERBYPASS
4+4140A
VALVE,OIL RL'fF_RBYPASS
4. 2485A
VALVE.OILPRESSUREREGULATOR
4. 1700C
W
WASHB:I,CRANKSHAFT
MAINBEAPJNG
THRUST
1.3100
WiRE
SPARK
PLUG
7.8715C
A/I_'c_on s=_ect_ochange
v,_tm__.
At/r_ reserved.
6SPI61_
© 1998DETROTT
DIESELCORPORATION
DETROIT
DIESEL
SERIES 60 ENGINE
AIR INTAKE
MANIFOLD
DRIVE
(7.4420)
DRIVE
(1.7600)
PUMP
(2.2001)
--
-FAN DRIVE
SPINDLE
ASSEMBLY
(5.4102)
--
VIBRATION
DAMPER
(1.3210) -AIR COMPRESSOR
(12.4030)
FUEL FILTER
(PRIMARY)
(2.3320)
STARTING
MOTOR
('/.3001)
FUEL FILTER
(SECONDARY)
(2.3010)
ELECTRONIC
CONTROL
MODULE
(2.1501)
--
AIR COMPRESSOR
(12.4001)
TYPICAL SERIES 60 ENGINE
SHEET 1 OF 2
© 1993 DH I HOlT DIESEL CORPORATION
DETROIT
DIESEL
SERIES 60 ENGINE
TURBOCHARGER
EXHAUST MANIFOLD -(6.1001)
(3.5001
ROCKE!
(5.2050)
(1.845o)
HOUSING
(1.5001)
J
t
L....¢;
WATER PUMP
(5.1001)
- BYPASS
OIL FILTER
(4.2250)
OIL PAN
(4.7001)
FLEX PLATE
(1.4085) --
OIL COOLER
(4.4001) --
--
OIL FILTERS
(4.2250)
TYPICAL SERIES 60 ENGINE
SHEET2 OF 2
© 1993 DETROIT DIESEL CORPORATION
DETROIT
DT ESEL
CUSTOM PARTS CATALOG 03/20100
06R0535792
PART #
1. 1000
NAME AND DESCRTpTZOG
QUANTITY
- CYLINDER BLOCK
1. 1001
BLOCK, CYLINDER
FOR COMPONENTS OF CYLINDER BLOCK ASSEMBLY REFER TO ASSEMBLY BREAKDOWNpAGE
A1
23522886
BLOCK ASSY. ,CYL.TLC FOR ARTICULATED STL
1. 1001
BLOCK, CYLINDER
23506222
BOLT, 148 X 1.25 X 20 12 PT.
5139988
PLUG, CUP 1" DZA. STNLS.
5139991
PLUG, I-1/2"
CUP (1.1001)
5151272
PLUG, 11/32"
SPECIAL (1.8180)
8522327
PLUG, 1/4" NPTF (12.9550)
8923516
PLUG, 1/2" PIPE (12.9550)
8924517
PLUG, 3/8"-18
SO. SOC. VIBRA SEAL (12.55S0)
8929124
BOLT, 1420 X 178.0
8929125
WASHER, SPECIAL
8929276
CAP, MAIN BEARZND (UNSLOTTED)
8929594
PLUG, 3/8"-18
DZA..PIPE
EXT. HEX. SOC.
1. 1025
NOZ2LE, PISTON COOLING
23521376
m_'7[E ASSY. ,PSTN CLG ARTICULATED STL
23906222
BOLT, ND X 1.25 X 20 12 PT.
23516104
PLUG PIPE 1/4-13
FEX HD STL CTD RED
8922327
PLUG, 1/4"
NPTF (12.9580)
8929432
PLUG, WEEP HOLE (SPECIAL)
23509239
STUD.N12X1.79X34.0
8929015
DOWEL PIN,
16 MM., CIRCULAR (1.1001)
8929022
DOWEL PIN 19 1414., DIAMOND ( 1. 1001 )
8929152
PIN, DOWEL 20.0 MM CIRCULAR
8929153
PIN, DOWEL 20.0 1414DZJ_IOM)
1
6
2
5
1
2
2
3
14
14
?
1
6
6
1
4
8
1
1
2
1
1
1. 1002
GASKET KIT, ENGINE OVERHAUL
A GASKET KIT CONSISTS OF THE NECESSARy GASKETS FOR ONE COII=LETE ENGINE OVER
HAUL.
23512691
GASKET KIT W/SC_
RING SEALS
AR
1.2000
-
CYLINDER HEAD
1.2001
I-EAD ASSY., CYLINDER
FOG C_14PONENT$ OF CYLINDER HEAD AS$ENELIES REFER TO ASSEMBLY 9REAKDOMN pAGE
A1.
23523294
H_AD ASSY.,
3 BOLT W/RACE TRACK DESIGN
1
_/ITHQU'r VALVES
1.2001
HEAD ASSY. ,CYLINDER
23511573
PLUG, 3/4"
PIPE SO. 5(3(:. SCOTCHGRZP
1
23511574
PLUG, 1" PIPE SO. SO(:. SCOTC3qGRIP
1
23513197
PLUG, 3/8"-18
PIPE SQ SOC COATED
2
510915?
PLUG, 1-1/4"
CUP (5.5001)
11
5139991
PLUG, 1-1/2"
CUP (1.1001)
2
852384?
PLUG, PIPE 1/4-18"
NPTF
1
8923916
PLUG, 1/2"
PIPE (12.9950)
2
8926993
PLUG, FUSE (1/4"-18
RECESSED $0C. HD.)
1
8929126
INSERT,
(EXHAUST) (STD) (6.261MM-6.38314M)
12
392912?
INSERT, (INTAKE) ($TD) (7.1SSMM-?.2571UM)
12
8929625
INSERT, (INTAKE) (.010"
U.S. ) (6.901NE-7.OO3NM)
AR
8929626
INSERT, (INTAKE)
(.020 u U.S.)
(6.647NN-6.?49NN)
AR
852992?
INSERT, (INTAKE) ( .030" UoS.)
(6.3531R-6.4951M)
AR
8929628
INSERT, (EXHNJST) (.010"
U.S.)
(6.007MM-6.10g14M)
AR
8929829
INSERT, (EX_)
(.020"
U.S.)
(5.753114-6.895J4)
AR
8929630
INSERT, (E]Q4AUST) (.030 U.S.)
(5.499MN-5.601GN)
AR
23518571
GUIDE
24
23522645
CAP, #1 _
BEARENG FRT RACE TRACK SEAL
1
8929739
CAP, CJU4SItAFT BEARING, REAR (IDENTIFICATZON-HO.
?)
1
8929870
CAP, CAMSHAFT BEARING, INTERMEDIATE (1,7042)
4
8529871
CAP, CAMSHAFT BEARING, CENTER (IDENTIFICATION-NO.)
1
5138635
DOWEL, .626"X.37"
HOLLOH (4.1040)
?
8925843
DOMEL, CAMSHAFT DRIVE C1.7004)
3
8529125
BOLT, M12 X 1.75 X 65
?
1.2045
TUBE, INJECTOR HOLE
23501580
TUBE KIT (INCLUDES SEAL RING IN 1.2046)
5
1. 2046
RING, ZN_ECTOR HOLE TUBE SEAL
23515470
SEAL RING ZNJ TUBE GREEN FLUOROCARBON
6
1
DETROIT
D$
CUSTOM PARTS CATALOG
06R0535792
PART
1.2000
#
NAME AND DESCRIPTION
- CYLINDER
8929123
8929328
R23525565
EFFECTIVE
WITH
•
BOLT,
MIB X 2 X 175 (12.9005)
WASHER,
16.8 _ X 25°8"
(12.9190)
HEAD ASSY.,
3 BOLT THRUST pLATE W/RACE
5R37024
WITH 23506350
EXHAUST VALVES.
*
UNITS
1.2010
GASKET,
23522588
-
CYLINDER
HEAD OVERHAUL
OF ALL GASKETS NECESSARY
GASKET KIT
CYLINDER
HEAD
GASKET,
ENGINE,
LIFTER
1.2070
BRACKET,
8929754
11509530
ENGINE
1.2080
BRACKET,
8925408
2351B_2
11509528
ENGINE
1.3000
-
QUANTITy
HEAD
1.2002
GASKET KIT,
GASKET KIT CONSISTS
23501572
1.200OA
ESE
L
03/20/00
CRANKSHAFT,
OIL
TO REPLACE
TRACK
COMPNEESZON
CYLINDER
HEAD
1
BRACKET
LZFTER-FRONT
BRACKET ( ITEM 1 )
BOLT, M14 X 2.0 X 40 NM
LTFTER
- REAR
BRACKET ( ZTEM 2)
BRACKET ENG LFTR
BOLT,
M12 X 1.75
SEALS
AN_
1
2
RR LB ND PLATED
X 30 1414
1
1
5
$80
STARZLZZERS
AND GASKETS
8EARZNG AND GASKET
KIT,
BRG GROGVELESS
1.3040
SEAL,
NOTE
HEAD.
AR
LOWER ENGZNS BEARINGS
LOWER ENGINE
23527914
SEAL
ONE CYLINDER
1.3001
CRANKSHAFT
ASSY.
NEW _FTS
FOR WIDER CONN ROD BEARINGS
AND CONN ROD ASSYS.
D TOGETHER TO ENSURE ZNTERCHANGEABZLZTY.
2382288?
CRANKSHAFT,
14.OL
188 STROKE
1.3003
KIT,
23519901
38
38
AR
CP,N4KSHAFT
L_dER
END
KIT
1850
MUST
BE USE
1
43144
ARTZC
AR
STL
AR
0TL-FRONT
AR
SEAL
1.3060
SEAL,
NOTE
CRANKSHAFT
(REFER
TO
1.3166
IN
1.300OA)
TO
1.5004
ZN
1.500OA)
0TL-REAR
AR
SEAL
1.3085
SLEEVE,
NOTE
C_FT
(REFER
REAR 0ZL
SEAL
AR
SLEEVE
(REFER
TO 1.5012
ZN
1.500OA)
1.3090
SHELL,
_SHAFT
MAIN BEARING
A SHELL SET CONSISTS
OF ONE UPPER AND ONE LOWER BEARING
SHELL.
...SOME
U_ZTS MAY REQUIRE
A LOWER MAZN THRUST KIT.
REFER TO YOUR CYLINDER
LOCK TYPE IN 1. 1035 IF REQUIRED.
8929870
SHELL SET,
STANDARD (MAZN)
8929871
SHELL SET,
.254NM UNDER SIZE
(MAIN)
8929672
SHELL SET,
.BO8MU UNDER SIZE
(MAIN)
8929873
SHELL SET,
.762NI4 UNDER SIZE
(MAIN)
8929680
SHELL SET, STANDARD (THRUST)
8929681
SHELL SET,
.254m4
UNDERSIZE
(THRUST)
8929882
SHELL SET,
.BOBMM UNDERSIZE
(THRUST)
8929683
SHELL SET,
.762144 UNDERSIZE
(THRUST)
1.3100
8929085
8929697
8929898
WASHER,
1.3110
8929278
CAP_
1.3140
8929124
BOLT,
CRANKSHAFT MAIN BEARING
THRUST
WASHER,
(UPPER THRUST ONLY)
WASHER,
.127414
0. S.
WASHER,
.254144
O.S.
CRANKSHAFT MAIN BEARING
CAP, MAZN BEARING
(UNSLOTTED)
CRANKSHAFT MAIN BEARTNG CAP
BOLT,
1420 X 178.0
2
B
6
AR
AR
AR
1
AR
AR
AR
2
AR
AR
7
14
DETROIT
DT
CUSTOM PARTS CATALOG
06R0535792
PART
1.3000
#
NANE
- CRANKSHAFT,
8929125
1.3145
GEAR,
23513537
8929497
8929808
1. 3000A
-
OIL
ESEL
03/20/00
AND DESCRIPTION
SEALS _
STABILIZERS
MASHER, SPECIAL
14
CRANKSHAFT Tt'MI"NG
t#-IEEL,TINZNG
RING (2.3145)
GEAR. l_'l,
82T,
133.ENN
I.D.
KEY,
.25"X1.375"
(12.9350)
CRAM<SHAFT
1.3158
HOUSING
23505875
FRONT
ASSY.,
QUANTITY
1
I
1
12.7L
COVER
8929760
8929015
8929022
8929740
GEAR CASE
HOUSING ASST.,
REAR MOUNT MATER PUI_
(INCLUDES
8929333
BOLTS & DOWEL PINS
SUPPORT
( 1.3160)
DOWEL PIN,
16 181.,
CIRCULAR
(1.1001)
DOWEL pIN
16 144.,
DTANONO ( 1. 1001 )
SEAL, RING
. 134X.O74X.480
I.D.
23505062
11503454
11505299
11513811
181333
8929333
5155596
5180370
BOLT,MlO X 1.5 X 40
BOLT, NlO X 1.5 X 20.0
BOLT, NlO X 1.5 X 30.0
IOI
BOLT, 1412 X 1.75
X 20 1414
BOLT, 5/16"-24
X .625 m
BOLT, N12 X 1.75
X 65 (SPECIAL)
MASHER, 21/64"
SPECIAL
COPPER (4.7120)
WASHER, .55"
I.D.
COPPER (7.4959)
GEAR CASE
COVER, FRONT
BOLT, 118 X 1.25
X 14 144
SEAL, RING
(3.4143)
PLUG, 318"-18
Sq. SOC. v'rBRA SF.AL
BOLT,
MlO X 1.5 X 55 144
BOLT,
NtO X 1.5 X 110 184
GUARD, BOLT V18 DNPR & FRT CVR
CRANKSHAFT OIL FRONT
SEAL FRONT (:R/SHAFT
1.3191
COVER,
23517382
8929099
11504822
ENGYNE
1.3192
GASKET,
8929255
8829130
ENGINE
1.30005
-
VIBRATION
1.3210
DAMPER,
23525990
1. 3000C
-
1.3280
8523077
8929222
5133981
1.40OOA
-
1.3158)
1
1
1
1
)
1.3158
COVER,
23505878
11504386
5141452
892451?
11509523
11503525
23507422
1.3168
SEAL,
23518355
1
IN
(12.9550)
1
2
1
1
14
4
1
MARPAROOND
1
FRONT ACCESSORY DRIVE
COVER, ACSRY REAR 6 HOLE
COVER, FRONT ACCESSORY
BOLT, 148 X 1.25
X 30
1
2
11
FRONT ACCESSORY DRIVE
GASKET,ACCESSORY
FRONT
GASKET,
UPPER RIGHT REAR & FRONT
CAN ACCESS.
2
1
DANPER
VIBRATION
DN_IPER,
CR..AqEr,
SHAFT
PULLEY,
CR UNITIZED
9
2
4
1
1
3
1
1
VIB
CR/SHF
13.5"
DI"A 1 PC
PA
14
1
3)
1
6
6
PULLEY
CRA_W,SHAFT
PULLEY,
188.0181
O.D.,
4
BOLT, 9/16"-18
X 2 1/2"
MASHER,
19/32"
(1.1(]01)
GROOVE
(ITEN
FLYk_IEEL
1.4001
FLYWHEEL ASSY.
INCLUDES
GEAR IN 1.4010.
"C" INDICATES
A CHAMFERED ASSY.
23514751
FLYt_EEL
ASSY,SAE1
TYPE 1,GNHD & 1.76
5100532
PLATE,
SCUFF (BEARING
RETAINER)
9410925
BOLT, 9/16"-18
X 2 1/4"
(12.9001)
1
1
12
1.4010
5184773
1
GEAR,
FLYWHEEL
RING
GEAR,
SAE
#1,
118
3
TEETH,
_ERED
DETROZ
T
DZ ESE L
CUSTON pARTS CATALOG 03/20/00
06R0535792
PART #
1.5000A
-
NAN[ AND DESCRZPTZOG
QUANTZTY
FLYb'HEEL HQUSZNG
1.5001
HOUSZNG ASSY. , FLYWHEEL
23522639
HOUSTNG ASSY FLYblHEEL SAE #1
1.5001
HOUSZNG ASSY., FLTklHEEL
23Sl1574
PLUG, 1" PZPE SQ. BOG. SCOT(]'IGRZP
23514442
PZPE PLUG 1 1/4 7/8 TPR SQ SOCHD
5106899
pLUG, 3/4u-16
23522327
BOLT M14 2.00 X 50.0 LG HEX HID
23522329
BOLT M14 2.00 X 55.0 LG HEX HO
23522326
MASHER
1
1
1
8
4
12
1.5004
SEAL,
23519651
1
1.8000
-
CRANKSHAFT OZL
SEAL, REAR CR/Sh'F
1
CONNECTZNG ROD AND PZSTON
1.6001
_CTZNG
ROD ASSY.
QUANTZTZES _
ARE PER CYLZNDER. A CROSSHEAD ROD ASSY. ZNCLUDES A CAP. I_1
ZCH ZS NOT SOLD SEPARATELY, AND ONLy THOSE ZTENS ZN 1.6001.
NEM CR_S
FOR WZDER C_
ROD BEARZNGS AM) GONN ROD ASSYS. NUST BE USE
D TOGETHER TO ENSURE ZNTER(]tANGEABZLI"TY.
23524956
ROD ASSY., CONN PLATED GROOVED BRASS BUSHZN
1
1.6100
SHELL, _CTZNG
ROD BEARZNG
A SHELL SET CONSZSTS OF ONE (1) UPPER AND ONE (1) LDtO!R BEARZNG SHELL.
NEW _S
FOR WZDER CONN ROD BEARZNGS AND _
ROD ASSYS. NUST BE USE
D TOGETHER TO ENSURE ZNTERCHANGEABZLZTY.
23525141
SHELL SET, STD COM_ ROD DRZLLED UPR/LWR 14L
1
1.15110
PZSTOR KZT
A PZSTON KI"T ZNCLUDES PZSTQN ASSY., 3 PC. BUSHZNG, SK]rRT AND P'ZN ZN t .8140.
IEUANTZTZES SHOWN ARE PER CYLZIQER.
23525'738
KZT, DONE & SKZRT PSTN ASSY. ART STL 15:1
1
1.6115
RZNE SET, PZSTOR
RTNG SET CQNSTSTS OF SUFFZCZENT RZNGS FOR ONE (1)
23525573
RZNG SET
1
PESTON.
1.5120
RZNG, PZSTON CONPRESSZON
23522378
RZNG, TOP (31114 CHR FLSH 14L)
23522879
RZNE, _
14L
1
1
1.6130
RZNE,
23B22380
23522881
PZSTON OZL CONTROL
RZNG, PSTN OZL CONT 141,.
EXPANDER 14L
1
1
1.6140
PEN,
23522872
PZSTON
PEN, PZSTOIK STL ARTICULATED
14L
1
1.8150
RETAZNER, PTSTOG PZN
23521751
NETAZNER, STEEL PZSTOH Pl'N
2
1.6182
CYLZNEER KZT
A KZT INCLUDES ITEMS ZN 1.8110,
1,5115,
1.5140 AND 1.8181.
23525835
KZT, CYLZNDER ART STL PSTN 15:1
AR
1.5190
SEAL,
3325013
1
1.7000
GYLZNDER LINER
SEAL, CREVZCE
- C.N4SHAFT AN_ GEAR TRAZN
1..7001
CAI4SHAFT ASSY.
A CAMSHAFT ASSY. ZNCLUDE5 DOWEL ].N 1.7001.
23524912
CAMSHAFT & DOWEL ASSY., 44N/92,J/16E
33201'72
DOWEL, CAMSHAFT ( 1 .'7200)
1
1
1.7037
COVER, CAMSHAFT BEARZNG CAP
23514.718
COVER
RRCANSHF
SO0
115C1_511
BOLT, 148 X 1.25 X 20 NN
1
3
4
DETROIT
DIESEL
CUSTOM PARTS CATALOG 03/20/00
06R0535792
PART #
1. 7000
NAME AND DESCRIPTION
QUANTITY
- CANSHAFT AM) GEAR TRAIN
1.7040
BEARING, CANSHAFT
A BEARING SET CONSISTS OF ONE UPPER AND ONE LOWER BEARING SHELL.
8929690
BEARING SET (STD.)
8929691
BEARING SET. .254 HN O.S.
8929892
BEARING SET, .508 m4 O.S.
8929893
BEARING SET, .762 NG O.S.
1.7042
CAP, CAMSHAFT BEARING
23522648
CAP, #1 CAI4SHAFT BEARING FRT RACE TRACK SEAL
(USED WITH 23522975 RACE TRACK SEAL)
5525870
CAP, CANSHAFT BEARING, INTERNEDIATE ( 1. 7042)
8929871
CAP, CANSHAFT BEARING, CENTER (IDENTIFICATION-NO.)
8929739
CAP, CANSHAFT BEARING, REAR (IDENTIFICATION-NO.
8929740
SEAL, RING . 134X .074X. 450 I.D.
5138838
-DOWEL, .629"X.37"
HOLLOW (4. 1040)
:_ FIG.
1 OF 1.2000.
7
AR
AR
AR
1
7)
4
1
1
1
7
1. 7046
BOLT,
5929129
CPJ4SHAFTBEARING CAP
BOLT, N12 X 1.75
1. 7070
PLATE,
23521892
11504822
CAN AND BALANCE SHAFT THRUST
PLATE, CAN THRUST 3 BOLT
DOLT, N8 X 1.25 X 30
1
3
1.7075
SEAL,
23521894
8929318
CAMSHAFT THRUST PLATE
SEAL, CAN THRUST pLATE TO CYL HI) 3 BOLT
SEAL (GEAR HOUSING)
1
1
X 55
7
1. 7200
GEAR, CANSHAFT AND BALANCE SHAFT
89253?9
GEAR 111T
1
1. 7206
HOB, CANSHAFT P-.rAR
8929510
KEY, NON ROCK (12.5350)
23524885
PUBCANDRV
GEAR
23524882
BOLT, 1420 X 1.50 X 100.0
1
1
1
1.7220
GEAR ASSY., IDLER
A GEAR AND HUD ASSY. ZS SERVICED AS A COI4PLETE ASSY. ONLY.
23513559
GEAR AND HUB ASSY., BULL ACCSY. & CN4SHF DDEC ZZZ
8929445
BOLT, N12 X 1.75 X 35
1
4
1.7221
GEAR ASSY.,
8929322
1
ADJUSTABLE CANSHAFT IDLER
GEAR ASS¥. (ZNGLUDES BUSHING tiH;CH
SEPARATELY )
IS NOT SERVICED
1.7255
HOB, ADdUSTABLE IDLER GEAR
8929111
HUB
11509807
NUT, M12 X 1.75
8929336
PLATE, A[bJUSTNENT
1.7000B
1
3
1
- ACCESSORY DRIVE
1.7600
DRIVE ASSY., ACCESSORY
23509200
DRIVE ASSY. , 2 GROOVE 120.0
1 . 7605
PULLEY, ACCESSORY DRIVE
11509584
NUT, LOCK N24 X 3.0
8929532
PULLEY, 2 GROOVE 120.O14M
1.7627
HOUSING, ACCESSORY DRIVE
23509201
HOUSING
1.7640
SHAFT, ACCESSORY DRIVE
23509202
SHAFT, LRG BRG
1.7642
GEAR, ,_=CESS_.Y ORXVE SHAFT
8928310
GEAR
1. 7650
LOCKRZNG, ACCESSORY DRIVE
23509204
LOCKRZNG
8929062
LOCY,RING
1.7955
8EAR'rNG, AI_ES_Y
DRIVE
23509203
BEARING, BALL SGL.
8928024
BEARING ASSY.
5
1414PULLEY LRG BRG
1
1
1
1
1
1
1
1
1
1
DETRO
Z T
DZ ESEL
CUSTOM pARTS CATALOG 03/20100
06R0535792
PART #
NAME AND DESCRZPTZON
- ACCESSORY DRZVE
1.7680
SEAL, ACCESSORY DRZVE OZL
8925154
SEAL
8829253
SEAL, RZNG .139" X 4.609"
11504822
BOLT, M8 X 1.25 X 30
QUANTZTY
1.70009
1 .BOO0
"r.D.
(2.2280)
1
1
5
- VALVE AN;) ZN'tECTOR OPERATZNG MECHANZSM
1.8050
HARNEss ASSY. . 1NJECTOR
23513605
HARNESS EDU TO ZNJ
USES 12034222
TERNZNALS
1
1. 9060
ARM ASSY. , E:O'IMJST VALVE ROCKER
ARM ASSY. _NCLUDES BUSHZNGS, PZNS AND ROLLER ASSY. CONPONENTS ROT SERVICED
SEPARATELY.
23523174
(R) ARM & RLR ASSY. EXH NCR W/O OZL HOLE
9421740
PLUG, CUP 3/15"
(12.9320)
5
12
1. 8075
ARM ASSY. , ZNTAKE VALVE ROCKER
ARM ASSY. ZNCLUDES BUSHZNGS, pZNS AND ROLLER ASSY. COMPONENTSNOT SERVZCEO
SEPARATELY.
23520644
(R) ARM & RLR ASSY. ZNT RKR W/O OZL HOLE
5
1. 9090
ARM ASSY. , ;NJECTOR P.DCKER
ARM ASSY. ZNCLUDES BUSHZNGS, pZN$ AND ROLLER ASSY. COMPONENTS NOT SERVZCED
SEPARATELY.
R23513939
REMANUFACTURED 23513939
23513939
ARM ASSY., "rNj RJORCER RLR HONED BUSHZNG
AR
6
1.9135
SCREW, ROCKER ARM ADOUSTZNG
23505056
KZT, VLV. ADO SCREt/ INO & ZNTAKE ARMS
8929646
KZT, VLV ADd. SCREW EXH ARMS
23517283
BUTTON, VALVE SS0/60
23520013
SCREW ASS¥.,
$NT VLV ADO M/O OIL HOLES
23520014
SCREW ASSY.,
E_H VLV ADO W/O OZL HOLES
8829607
SCREW, W/3/16 _ ZNTERNAL SOCKET END
23514371
NUT, 3/8"-24
HEX J_
8929494
RETAZNER (1.80_0)
AR
AR
30
6
8
5
30
30
1.8160
SHAFT ASSY.,
23513530
23521734
23521111
23522975
8929588
8929740
9421745
2350070S
8929587
2
2
2
1
2
1
2
2
6
ROCKER
SHAFT ASSY., LUBRZTED (ZNCLUDES PLUG)
STUD/SEAL ASSY.
SEAL
SEAL, RACETRACK FRT CAMSHAFT CAP
STUD, M12 X 1.75 X 123.0 (1.8170)
SEAL, RZNG . 134X.O?4X.480
Z.D.
PLUG, CUP 1/2 u (12.9330)
NUT, M12 X 1.75
BOLT, M12 X 1.75 X 110.0 (1.7046)
1,8173
SPACER, ROCKER
8929586
SPACER (01.8170)
B
1.8310
VALVE,
23507504
EXHAUST
VALVE KZT (ZDENTZFZCATZON-H)
(ZNCLUDES SEAL ZN 1.8320 AM) LOCK ZN 1.8370)
12
1.8315
VALVE,
23501575
ZNTN<:E
VALVE KZT
370 )
(ZNCLUOES SEAL ZN 1.8320
ANO LOCK ZN 1.8
12
1. 8320
GUZDE, EXHAUST VALVE
23518571
GUZDE
23519572
GUZDE VALVE
23523930
SEAL EXH VALVE STEM (4 VLV)
24
AR
24
1.8330
ZNSERT, EXHAUST VALVE
8929127
ZNSERT, (TNTAKE)
8929525
ZNSERT, (ZNTAKE)
8929826
TNSERT, (ZNTAKE)
12
AR
AR
6
(STD)
(.010"
(.020"
(7. 155MM-7.2571G4)
U.5.)
(6.B01NM-7.OG3NM)
U.S.)
(6.647m4-6.749HH)
,
DETROIT
DT
CUSTON PARTS CATALOG
06R0535"792
PART
1.8000
#
NAME AND DESCRZPTZON
- VALVE
8929627
8929126
6929828
8929629
8929630
SPRlrNG,
1. 8360
8929076
9929534
8g29635
8929636
SEAT,
1.8365
8929105
ROTATOR,
1.8370
8929573
LOCK,
-
EXHAUST VALVE
SPRING
(YELLOW
STRIPE)
EJQ'IAUST VALVE SPRZNG
SEAT (2.2NK-2.4NN)
SEAT ( 2 . 45NI4-2.55NI4)
SEAT (2 . 701m_-2.90NN
SEAT (2.95NN-3.1Slim)
AR
12
AR
AR
AR
24
24
AR
AR
AR
)
VALVE
ROTATOR
EXHAUST
VALVE
LOCK,
24
SPRING
KEY EXHAUST
VALVE
SPRZNG
48
ROCKER COVER
1.8450
COVER
23522272
1 . 8455
GASKET,
23522269
1 . 8460
23522271
QUANTITY
AND ZNdECTOR OPERATZNG NECHANZSM
INSERT,
(ZNTAKE)
(.030"
U.S.)
(6.393NM-6.495NN)
ZNSERT,
(EXHAUST)
(STD)
(8.261NN-8.383MN)
ZNSERT,
(EXHAUST)
( .010"
U.S. ) (6.0071414-6.
109NN)
ZNSERT,
(EJG_IAUST)
(.020"
U.$.)
(5.753_//4-5.8551194)
ZNSERT,
(EXHAUST)
(.030
U.S.)
(5.4991R4-5.80flg4)
1. 8340
3929415
1 , 80QOA
ESEL
03/20/00
BOLT,
ASSY, ,
ROCY_R
COVER
ROCKER
COVER
GASKET,
ROCKER COVER
SLEEVE
ASSY.,
ROCKER
ROCKER
ASSY. ,
COVER
IOBLT
SNC VZNYL
ROD SEAL
ROCKER COVER
BOLT NOD SEAL
1
1
10
DETROZT
DIESEL
CUSTOM PARTS CATALOG 03/20/00
06R0535792
PART
2. IO00A
#
-
NAME AND DESCRZPTZON
FUEL
2. 1001
5237014
QUANTZTY
ZNdECTOR
ZNOECTOR
ASSY.
(R)
ZN_JECTOR ASSY.
,
IOMM (9-1.80
X
155)
2. 1040
R;NG,
ZNJECTOR
SEAL
FORMER STYLE EUI
INOECTOR
BODY USED 2-UPPER
AND 2-LOWER
SEAL
STYLE EUI ZNJECTOR BODY USE 1-UPPER
AND 2-LOWER
SEAJ. RZNGS.
5234702
RING,
SEAL UPPER
5234699
RING,
SEAL LOWER
2. 1270
8929088
8929021
8929393
2. 100OB
-
CLAMp,
ZNJECTOR
CLAMP
WASHER
BOLT,
NlO
ZN,JECTOR
CONTROLS
2. 1501
MODULE
R23518308
23514772
23512309
23512307
ASSY.
2. 1520
PLATE
23518935
11504803
ASSY.,
2. 1600
SENSOR,
235111?5
OIL
2. 1610
8929387
NAG.
SENSOR,
,
SENSOR,
NAG.
CRAIi_HAF'I"
SENSOR (TRS)
(ZNCLUDES
2-8928852
BOLT,
M8 X 1.25 X
SEAL
14 MM
RZNGS)
AZR TEMPERATURE
SENSOR ASSY.
2. 1650
SENSOR,
23522322
5182977
23522719
AIR
1
5
1
1
1
1
FUEL OR COOLANT TEMPERATURE
SENSOR ASSY.
OIL WATER FUEL & AIR TEMPERATURE
SENSOR ASSY.
COOL TEMP 3/4
IN.
BRS
AIR
TEMP PLSTC
DDEC
PRESSURE
SENSOR ASSY. AIR TURBO BOOST DDEC
RZl4G, SEAL (3.3055)
BOLT NS 0.8
X 20.0
LG HEX HD
HARNESS
COVER
1
1
IZI
1
IV
1
1
2
1
ENGINE
SENSORS TO DISCONNECT
HARNESS ASSY.,ENGZNE
SENSOR
STRAP,
NYLON (2.5255)
CLZP
BOLT,
MIO X 1.5 X 20.0
BOLT,
M8 X 1.25
X 14 tim
BOLT, 148X 1.25 X 20 NM
RECORDER
1
1
4
8
1
RING)
2. 1647
SENSOR,
23515250
2. 1900
TR;P
R23515448
R23515649
R23515888
P.23515689
R23515670
DDECIV
PRESSURE
SEAL
14 _!4
OIL,
2. 1720
HARNESS,
23524280
5101020
8929534
11503454
11504986
11509511
(12.9001)
ZDLER
SENSOR (SNS)
('IrNCLUES
1-8928652
BOLT,
148 X 1.25
X
INJECTOR
1
2
6
6
8
ELECTRONIC
CONTROL (ECM)
MODULE ELECT CONT 1409 12/24V
8 IN
LABEL I)DC ELECTRONIC
CONT
BOLT N8 1.25
SHOULDER 12 PT HD
ISOLATOR,
ECM I_
2. 1530
SENSOR,
23518092
23515251
COVER,
CURRENT
ELECTRONZC
OR FUEL PRESSURE
SENSOR,
OZL/FUEL
11504985
2. 1702
8929508
X 70.0
RZNGS.
ELECTRONIC
DZSTRIBUTOR
UNIT COLD
PLATE ASM COLD ECM END liT DDEC IIZ
SCREW, NSX 1.00X25.0
I_
11504986
2. 1820
8929388
X 1.5
8
ANALYSIS
CONTROL SYSTEM
REMANUFACTURED
23515448
RENANUFACTURED
23515849
pRO DRZVER PETERBZLT
FLUSH MT
pRO DRIVER
KENWORTH FLUSH NT
PRO DRIVER
FREZGHTLINER
FLUSH MT
8
1
9
1
1
4
2
AR
AR
AR
AR
AR
DETROIT
DIESEL
CUSTOM PARTS CATALOG 03/20/00
06R0535792
PART #
NAME AND DESCRIPTION
QUANTITY
2.t000B
- IN_ECTOR CONTROLS ELECTRONIC
R23515671
PRO DRIVER V0LVO FLUSH MT
R23515672
PRO DRIVER FORD FLUSH MT
R23516428
PRO DRIVER KENWORTH SURFACE MT
23515448
PRO DRIVER DETROIT DIESEL FLUSH MT
23515649
PRO DRIVER DETROIT DIESEL SURFACE MT
2.2000
-
AR
AR
AR
AR
AR
FUEL PUMP
2.2001
PUMP ASSY., FUEL
5EE ASSEMBLY BREAKDOWNPAGE AI.
23507409
PUMP ASSY., L.H. (GEAR CASE DRVN)
2.2010
BODY, FUEL PUMP
23506553
PLUG, STL 1/8-27
23511956
KIT, STATOR
23511961
5TATOR, FUEL PUMP
2.2012
PIN, ALIGNMENT
23500694
PIN, ALIGNMENT
2.2030
COVER, FUEL PUMP
23506551
SCREW
23506552
PLUG 3/8-18
PLASTIC F/PUMP BARNES $60
23506561
PLUG
23511955
KIT,
FUEL PUMP COVER
23511957
COVER, FUEL PUMP
8923535
PLUG 1/8-27
PLSTC SHPG BARNES F/PUP
2.2040
GASKET, FUEL PUMP COVER
23506547
GASKET, GOLD
23506548
GASKET, SILVER
23516117
GASKET, BLUE
23516_18
GASKET, AMBER
2.2060
BEARING, FUEL PUMP
8923526
BEARING, FUEL PUMP
2.2070
SEAL, FUEL PUMP OIL
23512243
SEAL, OIL SGL LIP
2.2087
GEAR, FUEL PUMP DRIVE
23511959
GEAR (.275)
23511963
KEY, FUEL PUMP DRV. GEAR
8923522
RING, GEAR RETAINING
2.2088
GEAR, FUEL PUMP DRIVEN
8923521
PIN, DRIVEN GEAR
8923522
RING, GEAR RETAINING
2.2089
SHAFT, FUEL PUMP DRIVEN
A SHAFT ASSY. INCLUDES GEAR NOT SOLD SEPARATELY.
23511960
SHAFT
2.2093
SHAFT, FUEL PUMP DRIVE
A SHAFT ASSY. INCLUDES ITEMS ZN 2.2093.
23511958
SHAFT, DRIVE
2.2130
VALVE ASSY., FUEL PUMP
23506560
SPACER. RELIEF VALVE
23506963
KIT, RELIEF VALVE (CONTAINS VALVE, SPACER AND PIN
23506564
PIN, SHEAR RELIEF VALVE
3923528
VALVE, FUEL PUMP
2.2160
SPRING. FUEL PUMP VALVE RETAINING
23505597
SPRING, RELIEF VALVE
2.2170
PLUG, FUEL PUMP VALVE
23506555
CAP, RELIEF VALVE
2.2180
GASKET, FUEL PUMP VALVE PLUG
23506556
SEAL, RELIEF VALVE
2.2292
HUB. FUEL PUMP DRIVE GEAR
23511964
COUPLING, FUEL PUMP
R23507409
REMANUFACTURED23507409
8929832
ELBOW, 90 DEG. 3/8 INV FLU TUBE 3/8 PIPE (12.9480)
23506222
BOLT, M8 X 1.25 X 20 12 PT.
2.2007
GASKET, FUEL PUMP TO ENGINE OR DRIVE ASSEMBLY
5150193
GASKET(FUEL PUMP TO DRIVE ASSY.)
2.2230
COUPLING,
8929479
FUEL PUMP DRIVE
COUPLING
1
1
AR
1
2
8
2
1
AR
1
2
AR
AR
AR
AR
4
2
2
1
2
1
2
1
1
1
AR
1
1
1
1
1
1
AR
2
3
i
(5.1010)
1
1
DETROIT
DIESEL
CUSTOM PARTS CATALOG 03/20/00
06R0535792
PART #
2.2000
-
NAME AND DESCRIPTION
QUANTITY
FUEL PIJNP
2.2240
DRIVE ASSY., FUEL PUNP
SEE ASSEMBLY BREAKDOWNPAGE 51.
8929253
SEAL, RING .139 m X 4.609"
I.D.
(2.2280)
8929785
DRIVE ASST.
2.2001
DRIVE ASSY., FUEL PUNP
23513205
ELI_,
90 DEG. 3/8"
FL TUBE 3/8"
PIPE
89241?5
ELBOW, 90 REG. 3/8"
STREET (12.9480)
2.2255
GEAR, FUEL PUNP DRIVE
8929786
GEAR, 15.875
NN I.D.
9411502
RING, RETAINING
(2.7470)
2.2260
ADAPTOR, FUEL PUNP DRIVE
8929474
ADAPTOR FUEL PUNP BRG SUPT $60
2.2292
HUB, FUEL PUNP DRIVE GEAR
8929787
HUB, 15.875
144 I.D.
11504822
BOLT,148X 1.25 X 30
2.3000A
- FUEL FILTER
2.3010
ELENENT,
23518481
_
1
1
1
1
1
1
1
1
5
STRAINER
FUEL STRAINER
FILTER, FUEL PRTNARY
2. 3080
COVER, FUEL STRAINER
5148023
COVER
8924517
PLUG, 3/8"-18
SQ. SOC. VIBRA
11505299
BOLT, N10 X 1.5 X 30.0 NN
1
1
3
2
SEAL (12.9550)
2. 3305
FUEL/AIR
SEPARATOR
23515444
PRO-C_
FUEL/AIR
SEPARATOR SIDE liT
23613543
PRO-CHEK FUEL/AIR
SEPARATOR REAR liT
23513542
@
INSTALLATION KIT FOR PRO-CHEK SIDE liT
0 INCLUDES HOSES AND HARDWARENECESSARY TO RETROFIT Ex'rSTING ENGINES.
2.3320
ELENENT,
23518482
FUEL FILTER
FILTER,
FUEL SECONOARY
1
2.3390
COVER, FUEL FILTER
23517075
VALVE ASST. ,FUEL SHUTOFF
5148171
COVER
23518092
SENSOR ASST.,
OIL WATER FUEL & AIR T/BPERATURE
11505299
BOLT, 810 X 1.5 X 30.0 NIl
2.3590
SEPARATOR, FUEL WATER
23514047
PROCESSOR ASST. , FUEL PRO 380 12V HEAT
23515125
PROCESSOR ASSY. , FUEL PRO 380 NO HEAT
23518638
PROCESSOR ASSY. , FUEL PRO 380 24V HEAT
23521628
KIT, ELENENT & G_T
H/SEA). RINGS 380/382
23518839
KIT, FUEL PRO 3805 NO HEAT W/O DIVERTER CAP
(W/NOUNTING HARm/ARE)
23516640
KIT, FUEL PRO 3805 12V HEAT W/O UIVERTER CAP
( W/NOUNTING HARDWAR.E
)
23516641
KIT, FUEL PRO 38QE 24V HEAT tt/O DIVERTER CAP
( W/NOUNTZNG HARI_ARE )
2.5000A
-
FUEL LINES
AR
AR
AR
1
1
1
2
AR
AR
AR
AR
AR
AR
AR
AND FUEL COOLER
2.5006
VALVE,
23509727
23518523
FUEL SUPPLY CHECK
VALVE ASSY, FUEL CHECK 3/8"
NPTF
CONN ASN.9/16-18
X 1.332 STGT
2.5060
HOSE,
BAHH0156
5929831
9929832
FUEL PUNP INLET
HOSE ASSY., #8 X 17.9 H&H
COI_IECTOR, STRAZGE-[T3/SFLD TUBE 3/8
ELBOtf, 90 DEG. 3/8 INV FLD TUBE 3/8
2.5070
CLIP,
2362448
11504585
STRAINER TO FUEL PU_
CLIp .889" DIA 3/8" BOLT CTD (12.8554)
BOLT, N8 X 1.25 X 14 NM
10
1
2
PIPE
PIPE
(12.3460)
(12.9480)
1
1
1
1
1
DETROIT
DIESEL
CUSTON PARTS CATALOG 03/20/00
06R0535792
PART
2.50OOA
#
-
NANE
FUEL
LINE (: AND FUEL
2.5115
HOSE,
BAHPO311
8929832
FUEL
2.5116
HOSE,
BAHPO185
23505247
COLD
2.5121
2352448
COLD
CLIP,
COOLER
H&P
FLD TUBE
PLATE TO FILTER
HOSE ASSY.,
#8 X 21.2"
TEE,
90 DEG 5/8"
TUBE
H&P
2 WAY 1/4"
PLATE TO FI"LTER HOSE
CLIP
.I598" 0IA
3/8"
FILTER
2.5180
2362448
CLIP,
CYLINDER
2.5255
5101020
SHIELDING,
FUEL
QUANTTTY
PI,INP OUTLET TO COLD PLATE
HOSE ASSY.,
#6 X 33.5"
ELBOW, 90 DEG. 3/8
INV
2.5180
HOSE,
BAHP0213
5529833
8929"725
5929832
2.5280
VALVE,
2350558"7
AND DESCRIPTION
BOLT
(TO
3/8
PIPE
PIPE
(12.9615)
(12.5554)
TO CYLINDER HEAD
HOSE ASSY.,
#8 X 23.7"
H&P
CONNECTOR,
3/8 m INV.
FL.
TUBE;
5/8"
PIPE
ELBOW,
.80"
RESTRICTION,
38"PIPE
)(5/16"
E/mm_/,
90 DEG. 3/8
ZNV FLD TUBE 3/8
PIPE
HEAD INLET
CLTp
.688"
DIA
FLEXIBLE
HOSE
STRAP, NYLON
3/8""
(2.5255)
SYSTEM sHUTOFF
VALVE 1/4"
NPTF
BOLT CTD
(12.9480)
(12.5554)
1
1
1
1
2
(12.9460)
(2.5210)
(12.5450)
1
1
1
1
1
2
1
11
DETROZT
DZ
CUSTI_I
PARTS CATALOG
06R0635792
PART
3.3000C
#
-
NAME AND DESCRIPT/ON
AZR _NTAKE
3.3301
AZR
23517434
11509528
11506799
8922327
8923916
3.3803
23517875
3. 5000A
-
INTAKE
GASKET,
AI"R
MANZFDLD
14AN'[FOLD AZR ZNT HDRI"Z 1/2
BOLT, MIO X 1.5 X 130 I_1
BOLT,
MIO X 1.5 X 70 m
PLUG,
1/4"
NPTF (12.9550)
PLUG,
1/2"
PZPE (12.9550)
ZNTAKE NANlrFOLD
GASKET AZR ZNT IIFD
STL
5C
BOSS
RUB CTD
50
1
5
2
2
1
550/60
3
TURBOCHARGER
GASKET,
1.27
TURBOCHARGER
O]CL SUPPLY
TUBE,
TURBO OZL
_CTOR,
3/8"
3.6502
5145994
TURBOCHARGER
OZL SUPPLY TUBE
CLI"p,
318"
TUBE X 1/2"
CLZP,
3.5505
TUBE,
23518514
23505039
11609511
56TRZM
SCRL
_
E
SPLY
I"NV.
NED _
FL. TUBE;
TURBOCHARGER
GASKET
OZL RETURN
(3.5505)
5/9"
PZPE
BOLT
(12.9480)
1
2
1
560
1
1
3
TUBE
TURBOCHARGER
01"L RETURN TUBE
CLIP,
.750"
DZA.,
3/8"
BRACKET,
CLI"p 90 DEG.
BOLT,
MIO X 1.5 X 20.0
NUT,
1118X 1.25
12
1
4
4
1
TURBOCI-IARGER OZL RETURN
TUBE TURBO OIL ORN FLEX 55 NED liT
ELBOW, 90 DEG FLD 3/4
TUBE
BOLT,
N8 X 1.25
X 20 RN
GASKET,
3.5507
CLZP,
2476233
5144629
11603454
11507036
A/R
TURBOCHARGER
EXItAUST INLET
COI_ECTZON
GASKET,
TURBO EXHAUST ]INLET
3.5500
TUBE,
23513188
8929833
3. 5506
_t629285
QUANTZTY
MANZFOLD
3. 6001
TURBOCHARGER
23524100
• TURBO ASSY GT47
8929169
WASHER (12.9190)
11606101
NUT, 11t0X 1.5
3.5307
8929529
ESE
L
03/20/00
1
BOLT
1
1
1
1
DETROZT
DZESEL
CUSTON pARTS CATALOG 03/20/00
06R(Y335792
PART #
4. IO00A
NAME AND DESCRZPTTON
QUANTTTy
- OTL pUMP
4.1001
_
ASSY., OIL
A PUMP ASSY. INCLUDES ][TENS ZN 4. 1040, 4. 1065, 4.10"/5,
P.23505888
REMANUFACTURED 23505886
23505886
_
ASSY. , RT. SIDE ENGZNE
23505885
DOWEL, SLEEVE OTL pUMP
8929011
pTN, 25L.,
DOWEL
11502828
BOLT, MIO X 1.5 X 40.0
8929393
BOLT, MIO X 1.5 X 70.0 (12.9001)
4. 1003
OVERHAUL KIT, OZL PUNP
AN OVERHAUL KIT INCLUDES ZTENS TN 4.1065,
23511065
4. 1030
SHIN,
23508?40
OVERHAUL
KIT,
OIL PUNP
SHIM
(.0055"
4.1075,
4. 1090
4.1520,
AND 4. 1220.
AR
1
1
1
2
2
4.1590
AND 4.1730
RT SZDEENGINE
1
THK. )
AR
4. 1040
BODY, OZL PU6P
BODY ASSY. ZNCLUDES BUSHINGS TN 4. 1050.
23505878
BODY ASSY., RT. SZDE ENGINE
1
4. t060
BUSHING,
235058?9
2
OIL PUMP BODY
BOSHZNG, SHAFT &DRIVE GEAR
4. 1065
SHAFT AND GEAR ASSY., OZL pUMP DRIVE
23505882
SHAFT & GEAR ASSY., OIL _
1
4. 1075
SHAFT AND GEAR ASSY., OIL pUNP DRIVEN
23507337
SHAFT & GEAR ASSY. , OIL _
1
4. 1090
GEAR, 0ZL PUMP DRZVI"
23505884
GEAR, 59 TEETH
1
4. 1220
COVER, OIL PUMP
A COVER ASSY. INCLUDES BUSHINGS TN 4. 1220
23506883
COVER ASSY, OIL PUMP
23505879
BUSHING,
SHAFT&DRZVE
GEAR
11509511
BOLT, 68 X 1.25 X 20 1414
11509514
BOLT, 148 X 1.25 X 50 Ill
1
2
2
2
4. 100013
- OZL DI"STRZBUTZON SYSTEM
4. 1510
PIPE,
23506683
11509514
OIL PUNP INLET
TUBE & SCREEN AS*Y, 5TL PUNP
BOLT, 148 X 1.25 X 50 Nil
1
2
4. 1520
GASKET, 01"L _
INLET pIpE
23505382
GASKET, OTL INLET TUBE TO PUMP
1
4.1540
BRACKET, OZL PUMP SCREEN SUPPORT
8929104
BRACKET
11505299
BOLT, 610 X 1.5 X BO.O NN
11502812
NUT,MIOX 1.6
2
4
2
4.1580
PIPE,
OTL PUNP OUTLET
23505890
TUBE, OIL PUNP OUTLET
23514767
NS
ELBOW ASN QIL ZNL & PRESS RLF VLV $80
4.1580
PZPE, OIL PUNP OUTLET
23514738
ELBOV, OIL INL & RELIEF VALVE
457008
pIN, 3/16"
X 1-1/2"
SPRZNG (12.9270)
4. 1620
SPRING, OIL PUNP OUTLET PIPE BYPASS VALVE
5128327
SPRING (2.98"
FREE LENGTH, 15 COILS,
4.1530
VALVE, OIL PUNP (XJTLET PIPE BYPASS
8922740
VALVE
5117957
SEAT
23505851
RING SEAL, OIL _
OUTLET
23505882
RING SEAL, OIL PUNP INLET
11504822
BOLT, 148 X 1.25 X 30
13
1
1
1
1
CLOSED F.I_S,
1
1
1
1
1
2
OETROZT
DZ
CUSTON pARTS CATALOG
06R0938792
PART
4. 10008
#
-
4. 1590
8929347
4. 1000C
-
ESE
L
03/20/00
NAME AND DESCRIPTION
OIL
DISTRIBUTION
GASKET,
OIL
OIL
QUANTITY
SYSTEM
PUNP OUTLET PZPE
GASKET (TO B_)'
PRESSURE
1
REGULATOR
4. 1670
REGULATOR,
OIL PRESSURE
A PUMP KIT
INCLUOES
PUMP ASSY. AND SEAL RING.
23512901
REGULATOR ASSY.
4. 1680
BODY, OIL PRESSURE REGULATOR AND RELIEF
457008
PIN,
3/16"
X 1-1/2"
SPRING
8929283
BODY, REGULATOR
4. 1690
SPRZNG,
OIL PRESSURE REGULATOR
5126327
SPRING (2.96"
FREE LENGTH,
4. 1700
VALVE,
OIL
PRESSURE REGULATOR
8922740
VALVE
4. 1701
SEAT,
OZL PRESSURE REGULATOR
23512900
SEAT
11504822
B0LT,
M8 X 1.25
X 30
1
(12.9270)
15
-
DZL
OIL
4.2291
8923347
OIL
-
ADAPTOR,
OIL
ENDS,
1
1
2
1
(12.9270)
15
COILS,
1
1
CLOSED
ENDS,
1
1
1
2
FILTER
4.2250
ELEMENT,
23518480
4.4000A
CLOSEO
1
4. 1871
RELIEF,
VALVE OIL PRESSURE
A PUNP KIT
INCLUDES
PIJNP ASSY. AND SEAL RING.
8921088
VALVE ASSY.
4. 1680
BODY, OIL PRESSURE REGULATOR AND RELIEF
457008
PZN, 3/18"
X 1-1/2"
SPRING
8921084
BODY, RELIEF
4. 1690
SPRING,
OIL PRESSURE REGULATOR
$126327
SPRING (2.96"
FREE LENGTH,
4. 1700
VALVE,
OXL PRESSURE REGULATOR
8922740
VALVE
4. 1701
SEAT,
OIL PRESSURE REGULATOR
5117987
SEAT
11504822
BOLT, M8 X 1.25
X 30
4.2000A
COZLS,
1
1
FILTER
FILTER,
LUBE OIL
FILTER
PLUG,
COVER
PIPE
1/4-18"
SPIN
ON
2
NPTF
1
COOLER
4.4001
CORE,
5247436?
OIL
COOLER ENGINE
CORE _
ENG OIL
CLR
10
PLT
860
1
4.4050
tlnIJSING,
OIL COOLER-ENGINE
23518638
HOUSING ASR OZL CLR 10 PLT 12L $60
4. 4050
HOUSING, OIL COOLER-ENGINE
8922327
PLUG,
1/4"
NPTF (12.9550)
23511873
PLUG,
3/4"
PIPE SQ. 80C.
$COTCHGRIP
23511574
PLUG,
1" PIPE
SQ. SOC. SCOTCHGRIp
23811873
PLUG, 3/4"
PIPE SQ. SOC. SCOTCHGRZp
23518104
PLUG PIPE
1/4-13
HEX HD STL CTD RED
1
4
1
1
1
4.4053
HOUSING,
23508392
1
4.4058
8929289
GASKET,
OZL
OIL
TRANSFER COOLER-FILTER
RING,
SEAL
t
ADAPTOR
COOLER HOUSING
RING,
SEAL
4.4110
ADAPTOR,
OIL
COOLER
AN ADAPTOR ASSY.
INCLUDES
4-PLUGS
1
IN
4,4110
PLUS
ITEMS
ZN 4.4140
23513840
N5
#
ADAPTOR ASM OIL CLR/FLTR
IOPLT
12LS60
4.4001
CORE,OIL
COOLER ENGINE
52474387
CORE ASM ENG OIL CLR 10 PLT $60
4.4030
GASKET,OIL
COOLER CORE INNER
23506247
GASKET, OIL COOLER HOUSING
14
AND 4.4150
1
1
1
DETROIT
DZ ESEL
CUSTON PARTS CATALOG 03/20/00
06R0535792
pART #
NANE AND OESCRTpTI"ON
QUANTZTY
4.4000A
- OZL COOLER
4.4050
HOUSTNG,OZL IDOOLER-ENGZNE
23507182
BOLT, SPL N8 X 1.25 X 73.0
23518638
HOUSZNG _
OZL CUR 10 PLT 12L S50
23507183
BOLT, SPL 148 X 1.23 X 33.0
4.4110
ADAPTOR,O1rL __r__LER
23518637
ADAPTOR _
O/CLR 10 PLT PF2100 FLTRS
23508392
R][NG, SEAL
23505062
BOLT, 1410 X 1.5 X 40
# NOT SERVZCED, USE COMPONENTS.
4.4112
GASKET,
23505902
4.5000A
3
1
7
1
2
4
ADAPTOR TO OZL COOLER HOUS][NG
RI"NG, SEAL BYPASS FZLTER
1
- OZL FZLLER
4.5070
COVER, OZL FZLLER HOLE
23507264
COVER
23511574
PLUG, 1" PZPE SQ. $0C. SCOTCHGRZP
11509511
BOLT, 148 X 1.25 X 20 Nil
1
1
4
4.5080
GASKET,
8929302
1
4.6000A
OZL F1"LLER HOLE COVER
GASKET, 4 HOLE (4,5007)
- DZPSTZCK
4.6001
DZPSTZCK
23506487
B
DZPSTZCK, TURNTZTE (X-31.49",
Y-1.03
B NOT SERVZCED, FOR SERVZCE USE 23515136
DZPSTZCK, 23515135
842 COPPER SEAL AND 23513883 ADAPTOR.
4.6020
GUZDE,
23513883
23513842
DZPSTZCK
GUZDE
SEAL OZL LVL GA ADAP
4.8030
ADAPTOR, DZPSTZ(3C
23506489
ADAPTOR,
OIL TUBE
23606486
B*
TUBE ASSY, OZL LEVEL TURNTI"TE
137401
NUT, 1/2"
ZNV. TUBE
* ZNCLUDE NUT ZN 4.8030
B NOT SERVZCED, FOR SERVZCE USE 23515136
DZPSTZCK, 23515135
842 COPPER SEAL AND 23513683
ADAPTOR.
4.5040
CLZP,
5153473
5145872
106251
11_11
11507036
u, Z-23.71
u)
TUBE ASSY., 23513
1
1
1
1
1
1
TUBE ASSY.,
23513
DZPSTZCI(
CLZP, 1/2" TUBE, 3/8 BOLT
BRACKET CLZP, 90 DEG.
WASHER, 5/16"X3/4"
BOLT, 148 X 1.25 X 20 _
NUT, 148 X 1.25
1
1
1
1
1
4.7001
PAN, OZL
01"L PAN ASSYS. ZNCLUDE PLUGS, ZNSERTS, SEAL RZNGS, AND NUTS ZN 4.7001
23521330
KZT ZNSERT OZL PN/
23522283
PN¢ ASSY., 5ZL RR $UNP
6923313
PLUG, 3/4" PZPE (12.9550)
6178994
PLUG, 3/4"-14
_TF PZPE (4.7080)
23520929
SEAL R'rNO
23622281
SLEEVE ASSY., OZL PAN BOLT 140D SEAL SYS
3
1
3
1
3
10
4.7030
GASKET,
23522279
1
4".7000A
4.8000A
- OZL pAN
QZL PAN TO BLOCK
GASKET, OZL PAN W/O CORD HOD SEAL SYS
- VENTZLATZNG SYSTEN
4.8001
PZPE ASSY,
23505906
33513398
BREATHER
TUBE,BREATHER
DRAFT
HOSE, 1.25"XS.50"L.
15
1
1
DETROZ
T
DZ
CUSTOM PARTS CATALOG
05RO535792
PART
4.5000A
#
-
4,8039
5104958
5188840
ESE
L
03/20/00
NAME AND DESCRZPTZON
VENTZLATZNG
CLAMp,
4,8040
CLZP,
23509307
23506443
11504985
11509511
11507038
QUANTZTY
SYSTEM
BREATHER TUBE
CLAMP,
CLAMP,
BREATHER
1
1
1/2"-2"
CLAMPZNG RANGE
1/2"
I".D.
(12.96150)
TUBE
BRACK_I"
CLIP,
#16 HOSE
BOLT, M8 X 1.25
BOLT, M8 X 1.25
NUT, M8 X 1.25
1" OZA. (4.8183)
X 14 NM
X 20 MM
16
{12.9560)
1
1
1
2
1
1
1
DETRD
ZT
DZ
CUSTOM PARTS CATALOG
06R0535792
PART #
5. 1000
-
5SEL
03/20/00
NAME AND DESCRI"pTlrON
FRESH
WATER
QUANTZTY
PUMP
5. 1001
PUMP ASSY. , FRESH WATER
A PUMP KZT I"NCLUDE5 PUMP ASSY.
ANO SEAL RTNG.
23518215
NS
PUMP ASN WAT RR GRCASE SQCUT O-RG $80
5. 1030
BODY,
FRESH WATER pUMP
23511573
PLUG,
3/4"
PZPE SQ, SOC. SGOTCHGRTP
23511574
pLUG,
1" PZPE SQ. SOC. SCOTCHGRI"p
23517027
BODY WAT _
RRGL_CASE SQCUT O-RG $80
8929594
PLUG,
3/8"-18
DTA.
PIPE
EXT. HEX. 50C.
5. 1031
COVER.
FRESH WATER PUMP BODY
8922383
COVER, NQN-METALL 1"C
5. 1032
GASKET,
FRESH WATER PUMP COVER
23512048
SEAL RZNG
8522407
RTNG
RETAZNER
B. lOr-'.O SHAFT ASSY.,
FRESH WATER PUMP
23_56
SHAFT
5. 1070
BEARING,
FRESH WATER PUMP
8929422
BEARZNG ASSY.
5. 1071
RETAINER,
FRESH WATER PUMP BEARI'NG ANO SEAL
8529427
RZNG
5.1110
IMPELLER,
FRESH WATER PUI_ :D
23517973
ZMPELLER W/PMP C/Z 6 VANE $60
5.1130
SEAL,
FRESH WATER PUMP
23518316
SEAL WAr PUMP UNZTZZED
$80 W/SEALANT
8929134
SEAL,
LZP TYPE
5.1190
GEAR.
FRESH WATER pUMP DRZVE
2350589"7
WASI_R,
SPL WAr PUMP GEAR (5.1110)
23505910
GEAR,RH 61 TEETH
23508863
BOLT, M12XI.
75X50. OMN
23522707
(R) KI"T, WATER PUMP NT RR GR CASE
23505025
SEAL RlrNG W/SQ CUT (5.1032)
11509523
BOLT,
MlO X 1.5 X 55 Im
23505755
BOLT,
MlO X 1.5 X 155.0
5.1002
RECONDZTlrONZNG
K'rT,
FRESH WATER PUMP
A RECOI_E)ZTI"ONlrNG KZT ZNCLUDES SEAL RZI_
ZN 5. 1001,
BEAR][NG ZN 5. 1070 LOCK_Z
NG 'urn 5.1071
Alia) 1'TENS ZN 5.1130
AND 5,1236.
23509105
KlrT,
RECONDZTZONZNG
W/SQ CUT WAT PMP & CVR SEALS
5.20005
-
THERMOSTAT
5.2050
8529878
TI.ERNOSTAT
5. 2060
SEAL,
5132155
23509514
5.2120
COVER,
8929"/28
23511572
23511573
5136240
8924140
23505050
5.2000(:
-
ASSY.
THERMOSTAT
ASSY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
AR
2
1
2
2
1
1
4
TUBE
5.2165
8929875
WATER BYPASS TUBE
HOSE,
1 3/4"
X
WATER BYPASS TUBE
CLA_,
2"-2
1/2"
-
TEMP.
THERMOSTAT HOUSZNG
COVs=R
PLUG,
1/2"
NPTF $Q. SOC.
(12.5550)
PLUG,
3/4"
PZPE SQ. SO(:. SCOTCHGRZP
PLUG CAP .42"
DZA.
(2.2001)
DRAZNCOCK,
1/4"
(12.9510)
BOLT,
MlO X 1.5 X 85
WATER BYPASS
TUBE
5.30008
OPENZNG
2
1
1
1
2
AR
5.2180
TUBE,
23505598
5.2150
CLZP,
23505048
DEG.
THERMOSTAT
SEAL
SEAL
F_
WATER BYPASS
HOSE,
190
1
1
3.25"
WATER CONNECTZONS
17
DTA.
2
HOSE
4
DETRO
CUSTON
PART
5.30005
#
-
9.3400
23505899
TUBE,
WATER
5.3405
5929859
WATER
5.4010
QUANTZTY
WATER COI_ECTZONS
WATER
-
E$
E L
03/20/00
NAME AND DESCRZPTZON
9.3401
HOSE,
23506325
5. 4000A
ZT
DZ
PARTS CATALOG
06R0539792
CLZP,
PUMP TO OZL
TUBE (FOR
COOLER
HZ & NED liT.
TURBO)
1
pI.N4P TO OZL COOLER
HOSE, 2;75"X3.0"
L (BLUE)
2
PL_
TO OIL COOLER
CLAMP,
3"-3
1/2"
TUBE
ZD HOSE
4
FAN
BLADE,
FAN
5.4015
PULLEY
8929189
8929218
8929585
84090315
HZGH LOW AND CRA_FT
MOUNTED
( CUSTONER FURNZSHED )
BLADE
1
AND HOB ASSY.,
FAN
WASHER (12.9190)
PULLEY,
FAN 3 GROOVE 203.0,
1 GROOVE 254.0
BOLT,
MlO X 1.5 X 380.0
(12.9001)
BOLT,
3/8"-24
X 1.125"
(12.9001)
5. 4025
SUPPORT,
23S11356
11504822
11509525
11S09591
11509533
11513980
FAN
MOUNT_rNG
SUPPORT,
W/UPR RT BOLT BOSS
BOLT,
M5 X 1.25
X 30
BOLT,
NlO X 1.5 X 110 I04
BOLT,
U14 X 2.0
X 60 MM
BOLT,
M14 X 2.0
X 100 1414
BOLT,
1410 X 1.5 X 145 _
8
1
1
B
1
5
2
1
1
1
5.4102
5Pt[NDLE
ASSY.,
FAN DRlrV£
A 5pIrNDLE
ASSY.
INCLUDES
ZTEMS ZN 5.4102,
5.4103,
5.4111
AND 5.4180.
8525533
SPZHOLE ASSY.
455322
FlrTTZNG,
1/8"
VENT (12.9540)
271283
FZTTZNG,
45 OEG.-1/8"
GREASE (12.9540)
455734
PZN,
SPRZNG 1/8"
X 3/4"
(12,9300)
11500944
BOLT,
M12X1.75X40.O
PiN
5131978
WASHER,
.53 X 1.00
(1.5001)
8929214
WASHER
1
1
1
1
4
4
1
5.4103
8929215
8920419
1
1
HOUSZNG,
5.4111
BEAR][NG,
7451005
23506559
8523064
23518178
8929063
8829215
5.4180
8929213
SEAL,
FAN
FAN
DRZVE SPZNDLE
PLATE
BOLT,
NlOX1.5"X49.O"
SPECZAL
(1.20"70)
SPTNDLE
BF.J_.RZNG, ROLLER (12.4048)
BEARTNG,
BALL (OPTI"ONAL
TO 8929530)
RZNG,
I_r1" R,ETAZNZNG 3.121"
O.D.
(12.4048)
BRG BALL ALT DRZV HEAT 5TAB1[LZZED
$60
RlrNG,
ZNT RETAINZNG
3.'/34"
O.D.
(12.4048)
RZNG,
I"NT RETAZNZNG
1.618"
O.D.
(5.4111)
FAN SPZNDLE
SEAL
1
1
1
1
1
1
1
15
DETR6ZT
DZ
CUETON pARTS CATALOG
06R0535792
PART
8. IO00A
6.
6.
#
-
ESEL
03/20/00
NANE AND DESCRZPTZQ_I
EXHAUST
NANZFOLD
1001
NANZFOLD,
23611222
23611977
1010
GASKET,
23611668
AND/OR
EXHAUST
MANZFOLD,
NANZFOLD,
COM_ECTZONS
3 PC FRT & REAR END
CENTER,
3 PORT
EXHAUST 14ANZFOLD
GASKET,
2 PORT
3
NANZFOLD TO TURBOGHARGER
STUD, MIO X 1.5 X 44.0
4
EXHAUST
6.
EXI-IAUST NANZF6LD
TO HEAD
BOLT, 1410 X 1.5 X 120
SPACER
6.1171
HEAT
23513776
23509744
11506101
SHEEt.D,
2
1
(GRAPHZTE)
6. 1022
sTUD,
23507438
1025
BOLT,
8929367
23611867
QUANTZTY
(12.9001)
EXHAU6T NANZF6LO
HEAT SHZELD _
NFLD REAR
S'I1JD, BOLT M10X1.6X120.O
M.IT, MIOX 1.5
19
9
12
1
3
3
DETROZ
T
DZ
CUST_
PARTS CATALOG
06ROS35T82
PART
7. IO(X)A
_
-
NAME AND OES('_RZPTZON
BATTERY
CHARGZNG
7.1001
GENERATOR
19010182
442"/33
3427545
5132715
103323
10253"/
7. 1500
5140070
PULLEY,
7.15"75
BELT,
23519070
-
ASSY.
GEN CI,IRG AC 24V.70A NG CW/CCt¢ 215I
BOLT,
1/2"-13
X 1.25"
(12.9001)
mOLT,
1/2"-13
X 8.25"
(12.3001)
WASI'ER,
.53"X.94"X.12"
(1.3140)
LOC_ASHER,
1/2"
NUT,
1/2"-13
GENERATOR DR][VE
BELT SET
.7.1555
BRACKET,
23521125
23521130
8929357
23521131
5TART1rNG
QUANTZTY
G_NERATOR
GENERATOR
PULLEY,
7. 1580
STRAP,
23514316
23511869
103345
11501055
7. 3000A
ESEL
03/20/00
3.66"
DI"A,
2
GRVS
.900"
1
1
1
5
2
1
WI"DE
2/1"1C50
1
1
GENERATOR ADOUSTZIklG
ROD, ADOUSTZNG M16 X 2.0
L'r_,
ADJUSTZNG
ROD
W_t'ER,
5/R"
NUT, N15X2.0
X
222.0
GENERAT0t_ 14QUNTI*NG
BRACKET,
GENERATOR LOW NT
BOLT NIO 1.50
X 145.0
HEX FLG
BOLT, NIO X 1.5 X 120 (12.9001)
_
NlO GEX FLANGE
LG
CTD
1
1
2
2
1
2
1
4
NOTOR
'7.3001
JNOTOR ASSY.,
R0461128
10478980
9435720
103325
STARTZNG
NOTOR ASSY.,
24V 42141" (RENANUFACTURED)
NOTOR ASSY.
(24V.
CW. ZNSUL.
421_r)
_LT,
5/8"-11X2
1/4"
(12PT.)
(12.9005)
_ASHER,
5/8"
20
AR
1
3
3
DETROTT
DT
CUSTOM PARTS CATALOG
06RO535792
PART #
11. IOOOA -
ESEL
03/20/00
NAME AND DESCRTPTI"0N
ENGZNE
QUANTZTY
MOUNTZNG BASE
11.10"/O
SUPPORT,
8929744
11509528
8929068
ENGTNE FRONT
SUPPORT (WEST COAST)
ZTEM 1
BOLT,
M12 X 1.75
X 30 m4
BOLT, M14 X 2.0
X 140 (12.9001)
1
8
4
TYPE BREAKDOWN
FIG.
SERIES 60 PARTS CATALOG
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
PART
NO.
ASSY.
SECT.
NAME AND DESCRIPTION
12.8001
8929665
PAINT, ENGINE TOUCH-UP
pAINT,BLUE(1 GAL.CAI,t)
8929666
PAINT. BLUE (12 OZ. SPRAY CAN)
_R¢_r_P:_'7
__
PAINT, CLEAR (1 GAL. CAN)
892_68
PAINT, CLEAR (12 07-- SPRAY CAN)
12.8005
KIT, RLTER
MAINTENANCE-FUEL/OIL
23518018
23.518683
K_, FILTER MAINTENANCE
S50_0
W/235t6189PRtMAR_
K_, FILTERMAINTENANCE
S60
(PRE.-1993)
23.518686
K_, RLTERMAINTENANCE
$50Co0
(ls_-)
12.8006
FUEL SYSTEM PRODUCTS
__ ___'J047
FILTER ASSY.PRIMARY
23518168
SEA PRO 150
ELEMENTPPJMARY
30 MICRNSEAPRO 300
2351S125
PROCESSOR
23519956
23514047
23521049
23513S43
23516638
23.513542
30 MICRON
ASSY., FUEL PRO 380
NO HEAT
PROCESSOR
ASSY.,FUELPRO380
NO HEATCHROME
PROCESSOR
ASSY.,FUELPRO380
12V HEAT
PROCESSOR
ASSY.,FUELPRO380
12VW/GROUND
PRO-CHIE_FUE]JAIRSEPARATOR
REAR MT
PIROCESSOR
ASSY.,FUELPRO380
24V HEAT
INSTALLATION
KITFORPRO-CHEX
SIDE MT
23519957
PROCEESOR
12V W/FLUID
2351.5444
PRO-CHEKFUEL/AIRSEPARATOR
SlOEMT
PROCESSORASSY.,FUELPRO380
24VW/FLUIDHEAT
PROCESSOR
ASSY.,FUELPRO380
12VHEATV_FSENSOR
PROCESSOR
ASSY.FUELPRO380
12V/120VHEAT
IQ_,FUELPRO380ENOHEATW/ODI"VPJ-I
IfcMCAP
KIT,FUELPRO380E12VHEATW/O
DWEHICHCAP
KIT,FUELPRO380E24VHEATW/O
DIVk:HI¢H CAP
Krr,FUELPRO380F12VW/O_1_
VEHI_ CAP
KIT,FUELPRO38024VR.UIDHEAT
WK)DI_HI _HCAP
KiT,FUEl.PRO380ENOHEATW/DIV_HIES CAP
KIT,FUELPRO380E12VHEAT
CHROMEW/DIVERTER
CAP
KIT.FUB-PRO380E12VHEATW/DIVP-HIF._CAP
K_, FUELPRO380E24VHEATW/DIVERTER CAP
23519724
_Z__
__91_
__?_
_¢_0g07
2351_
23516640
23516641
23519239
23519725
23519237
23519238
23Sl 923.5
23519236
12.8000A
AESY., FUEL PRO 380
HEAT
SUPPLIES/MAINTENANCE
A1
A1
A1
A1
A1
A1
A1
A1
A1
A1
A1
A1
A1
A1
B1
B1
B1
B1
PRODUCTS
SSpl_ _os© 1998DETROITD_SE_CORPORATZON
SERIES
60 PARTS
FIG.
CATALOG
TYPE BREAKDOWN
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8006
FUEL SYSTEM PRODUCTS
(conL)
23519778
23516731
•
23518360
23518361
KIT FUEL PRO 380 12V/120V HEATW/
DIVE_
CAP
WRENCH,COLLAR FUEL PRO 380
(REMOVALONL'O
KIT,12VHEATER
UPGRADE(LONG
CAN)
_ 24V HEATERUPGRADE (LONG
CAN)
B1
AR
AR
AR
AR
12.8025
ATFBULK
OIL, ENGINE LUBRICATING
BULKMO_L MULTI-PURPOSE ATF
ATFDRUM
55 GAL MOBILMULT;-PURPOSEATF
AR
AI"FG _L
1 GAL- PAILM(_L MULTI-PURPOSE
ATF
I AR
ATFQUART
GREASEC
12 QUARTMOBILMULTI-PURPOSE
ATF
60x14 07_ CARTRIDGES MOBILGREASE SPECIAL
400 IJ3, DRUM MOB_LGREASESPECIAL
AR
120 LB. KEG MOBILGREASESPECIAL
60X14OZ,CARTRIDGES
MOBILGREASE HP
400 LB. DRUM MOBILGREASEHP
AR
AR
120 LB. KEG MOBILGREASEHP
AR
MOBIL424
SHCS00
55 GAL MO_LFLUID 424
375 LB. DRUM MOBILTRANSSHC 50
AR
AR
SHC50K
SHC50P
120 LB. KEG MOBTLTRAN
S SHC 50
35 LB. PAlL MOB_LTRANSSHC 50
AR
AR
23512703
1 GAL. DELVAC1300 SUPER 4 CYL
t AFt
23512704
ENG
S5GAL. DELVAC1300 SUPER 4 CYL
ENG
tj
AR
AR
AR
7b'_/901)
BULKDELVAC1300SUPER 4 CYL ENG
5 GAl- DELVAC1300 SUPER 4 CYL
ENG
55 GAL. SUPER GEO NATUPAL GAS
ENGINE
1 GAL POWERGUARD DELVAC1 4
CYL ENG
55 GAL.POWERGUARD DELVAC1 4
CYL ENG
400 LB. DRUM MOBILUBESHE;75W90
75Wg0K
75wgoP
120 IR, KEG MOB_LUBESHC 75W90
35 lB. PAILMOBILUBESHC 75W90
AR
AR
80W140D
400 LB. BARRELMOBILUBESHC
80W140
AR
80W140K
120 LB. KEG MOBILUBESHC 80W140
i AR
80Wl 40P
35 LB. PAILMOBILUIaESHC 80W140
AR
120 UB.KEG MOBILUBEHD 80W90
AR
GREASED
GREASEK
HPCART
HPDRUM
HPKEG
23512740
23512741
23518542
23520318
23520320
80=_/90K
80WgOP
85W140D
8b_N140K
80Wg0D
35 LB. PAILMOBILUBEHD 80Wg0
400 LB. DRUM MOBILUBEHD 85W140
400
120 LB.
LB. KEG
DRUM
MOBILUBEHD
MOBILUBEHD
85W140
80W90
85W140P
35 LB. PAILMOBILUBEHD 85W140
AR
AR
AR
AR
AR
AR
AR
AR
RAR
AA/_R
L
I AR
I
AIt_'f_rmata_n
subjectto changev,ithoutnotce..41t
nghtsresewa_
ss_s1 _=sos_ _99s_'rRorr DmsEt.com, o_ao_
12.8000A SUPPL1ES/MAIR_cP_J'qANCE PRODUCTS
TYPE BREAKDOWN
SERIES
12.8000A
RG
B
SUPPMES/MAINTENANCE
PRODUCTS
PART
NO.
)
60 PARTS
CATALOG
"
Nt
NAME AND DESCRIPTION
(Note: Assemblies are shown
for component reference
only.)
12.8006
FUELSYSTEMPRODUCTS
23515125
PROCESSORASSY., FUEL PRO 380
NO HEAT
23519956
pROCESSOR
ASSY.,
FUELPRO380
23514047
23521049
23516638
2_LS't9957
23519724
23521056
23520907
23516639
2_151_a40
23516641
23519239
23519725
23519934
23514049
NO HEAT CHROME
PROCESSORASSY., FUEL PRO 380
12V HEAT
pROCESSORASSt., FUEL PRO 38O
12V W/GROUND
PROCESSORASSY., FUEL PRO 38O
241/HEAT
PP,OCESSOR ASSY.,FUEL PRO 380
12V W/FLUID HEAT
pROCESSOR ASSY.,FUEL PRO 38O
24V W/FLUID HEAT
pROCESSOR ASSY.,FUEL PRO 380
12V HEAT WlF SENSOR
_
ASSY.FUEL PRO 380
t2V/120V HEAT
KI_, FUEL PRO 380E NO HEATW/O DIVCHIP.H CAP
_ FUEL PRO 380E 12V HEATW/O
DIVI_HIP.HCAP
_ FUB. PRO 380E24V HEATW/O
DIVI:H I P.._CAP
KiT, FUEL PRO 380F 12VW/O OlV_J_l ¢H CAP
I_, FUEL PRO 380 24v FLUIDHEAT
W/O D_EHIP.H CAP
STUD, 13/16"-12, 7/8"-14
ELB_ENT & GROMMET ASSY.380
i
1
•
_ 1
I
t
1
1
1
1
1
1
I
1
1
1
1
1
1
1
I
1
1
1
2
I
2
1
1
1
2
(USEW/23514_lKIT)
23514051
23516794
23516796
23514060
235167°_
23S14048
KIT, W/CAP& BOWL0-PJNGS
BRACKET,FUEL PRO 380 MOUNT
U-CLAMP ASSY., FUEL PRO 380
SPP_NG,FUEL PRO 380
U-BOLT,FUEL PRO 380
COVER, CLEAR FUEL PRO 380
1
1
1
1
1
I
I
_
I
I
1
1
1
1
1
23514061
2351b"797
COLLAR, FUELPR0380
WIRE HARNESS, FUEL PRO 380
1
i 1
;
1
1
I
1
1
1
1
23517429
"fEE,I./4"NPTF
23514043
2351g_=8
23S1_J43
23519944
Kn_,WiGAP&SEALPJNG
CIRCUIT BREAKER,FUEL pRO 380
VALV_INLET(2351_)
VALVE,CHECK THERM CONTROL INLET (23519967)
TERMINAL, BUTT SPLICE FUEL PRO
1
1
1
1
1
1
I
1
1
1
1
1
1
1
2
1
23519°_9
")_¢_q__1064
23518327
23.fil 9960
23S17427
23517428
23521060
23517426
23517425
23521061
VALVE,CHECK _
CONTROL
W/GRD INLET (23521066)
VALVEASSY., DRAIN _
PRO 380
RT'flNG, PIPE TO HOSE FUEL PRO
380
HEATER,
FUEL
PRO
38012V
HEATEFLFUEL PRO 380 24v
HEATER,FUEL PRO 380EE 120V
lOT,W/TPERMOSWITCH & W-RAP
HARneSS, _
PRO 380 12V,'24V
HARNESS, FUEL PRO380 12V
GROUNDED
12.8000ASUPPI .IF._MdNTENANCE
2
1
i
1
i 1
_
: 1
:
1
1
1
1
1
1
1
1
1
1
1
1
I
1
I
1
1
PRODUCTS
er,_sl 9.o9© z99sD_'r_orrv_+_-_
CORPORATION
SERIES 60 PARTS CATALOG
TYPE BREAKDOWN
12._000A
RG
PART
NO.
SUPPUES/MAINTENANCE
PRODUCTS
A B C D E F G H
I
NAME AND DESCRIPTION
(Note: Assemblies are shown
for component reference
only.)
12.8006
23521065
23521062
FUEL SYSTEM PRODUCTS
(cont.)
HARNESS, FUEL PRO 380E WlF SENSOR
SENSOR,
WATER
INFUEL
1
1
• NOT SERVICED, USE PART NUMBER
SHOWN IN PARENTHESES AND
23518326 REPAIR Kfl_
A__/orm_
6s_61 _
_
to changew/tho¢_
trace. A#r_s resa_ved
© 199soErRorrDIESEL
coP.PoP._oN
12.8000A SUPPLIES/MAINTENANCE
PRODUCTS
J K L M
TYPE BREAKDOWN
SERIES
12.8000A
FIG
SUPPMES/MAINTENANCE
PRODUCTS
PART
NO.
B
60 PARTS
CATALOG
E
NAME AND DESCRIPTION
(Note: Assemblies are shown
for component reference
only.)
12.8006
FUEL SYSTEM PRODUCTS
23519237
23514051
23516794
23516796
23514060
2351 b'-/zJ5
23514048
23514061
KrE FUEL pRO380E NO HEATWJDI_P..Ktv._ CAP
KI'_,R,EL PRO 3_0_ 12V HEAT
CHROME WAO_vP._li=HCAP
_ FUEL pRO 380E 12V HEATW_IVtcfK0Z:.HCAP
IG_, FUEL PRO 380E24V HEATW/DIVER'PER CAP
KIT FUEL PRO 380 12V/120V HEATW!
DrVEHP-H CAP
PROCESSOR ASSY.,FUEL PRO 380
12V HEAT
pROCESSOR ASSy., FUEL PRO 38O
NO HEAT
PROCESSOR ASSY.,FUEL PRO 380
24"VHEAT
STUD, 13/16-12, 7/8"-14
PROCESSOR ASSY.,FUEL PRO 380
NO HEAT CHROME
PROCESSOR ASSY. FUEL PRO 380
12V/120V HEAT
ELEMENT& GROMMET ASSY.380
(uss wr:23sl.4_ KZ'r)
I_, W/CAP& BOWl. 0-RINGS
BRACKET,FUEL PRO 380 MOUNT
U--CLAMPASSY., FUEL PRO 380
SPRING, FUEL PRO 380
U--BOLT,FUEL PRO 380
COVER, CLF_ARFUEL PFIO380
COLLAR, FUEL PRO 380
23516797
23514043
23S19¢J43
23519944
WIRE HARNESS, FUEL PRO 380
K_, W/CAP & SEALRING
VALVE,CHECK INLET (23519966)
VALVE,CH_=CK"RIERM CONIROL IN-
23519238
23519235
23519236
235197/'8
23514047
23S1512S
23516638
23519934
23519956
23520907
23514049
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I
I
LET(23Slg,J67)
23518327
23517427
23517428
23519116
23_t060
23517426
23517425
23S1_J58
23519959
23521068
VALVE ASSY., DRAIN FUEL PRO 380
HEATER, FUEL PRO 380 12v
HEATER, FUEL PRO 380 24V
CAP ASS,(., DIVERTER 13/16-12,
3.225" SEALID
HEATE_ RJEL PRO 3a0BE 12W
KI'E,W_
& TY-RAP
HARNESS, FUB. PRO 38012V/24V
GIRcurr BREAKER,FUEL PRO 380
";EFa_IINAL,B.)'TT_=IJCE FUEL PRO
38O
CORD, ELEC. HEATER
• NOT SERVICED, USE PART NUMBEF
23518326
_-- :....
REPAIR KIT.
12.8000A SUPPLIES/MAINTENANCE PRODUCTS
Aa;rd_,,,_on _,p_ to ch_ge wttr_t notCe.A_rightsmsmy_
ss_sl uos© 1998 Db'TROITDIESFA.CORPORATION
TYPE
BREAKDOWN
SERIES
12.8000A
SUPPLIES/MAINTENANCE
FiG.
PART
NO.
PRODUCTS
60 PARTS
CATALOG
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8070
HAND CLEANERS
23523182
HAND CLEANER FAST ORANGE
SMOOTH LOTION 15OZ BOTTLE
AR
23523185
HAND CLEANER FAST ORANGE PUMICE LOTION 15OZBOTT'LE
HAND CLEANER TROLINCELOTION
_5OZ BOI"P,..E
AR
AR i
23523184
HAND CLEANER FAST ORANGE
SMOOTH LOTION1GAL BOTt'LE
HAND CLEANER FASTORANGE PUMICE LOTION 1GALBO'rI_E
23523186
HANDCLEANERTROUNCELOTION
1GALBo'rrLE
2:3523223
BRACKET,WALLMOUNT 1GAL PUMP
BOTTLE
23523187
23523183
12.8110
i
AFt
;
AR
AR
LUBRICATING COMPOUND
THREAD
5198563
23_545
12.8242
INTERNATIONALCOMPOUND #2 QT.
AR
SEAL ANTI-SEIZE HEAT & RUST 1 LB.
AR
THREADLOCK & SEALER
23509535
THREADLOCK, MEDIUM STRENGTH
AR
ME)
2350¢J536
23._9
3_,READLOCK, MEDIUM STRENGTH
(10 ME)
THREADLOCK, HIGH STRENGTH (10
ML)
_]READLOCK, HIGH STRENGTH(50
ML.)
THREADLOCK. PENETRATING(10 ME)
I AR
235043542
23509544
SEALER,THREAD (50 ML)
SEALANT.COMPOUND (50 ME)
AR
AR
23509537
12.8255
AR
AR
AR
SEALANT, RTV
23509540
AR
23523064
SEALANt. GASKET ELIMINATOR(50
ML.)
SEALANT, GASKET ELIMINATOR
(50ME)FOR INSTALLINGFRT & REAR
CAMSHAFT CAPS
23509541
sEALANT, GASKET ELIMINATOR(3O0
AR
23509543
23509603
SEALANT,ULTRA_-UE RTV 3 OZ.
SEALAN'_,BLACKFRV 11 OZ.
AR
23523188
SEALAN'E,HIGH TEMP RED RTV 11 OZ.
V,L4
12.8000A SUPPLIES/MAINTENANCE
AR
PRODUCTS
Nt/nfmmatoqs_
to_
vd_t_._n_/ce.At1n_ts mse_ea.
ssmsl 98_© 1998DETROIT
DIESEL
CORPORATION
SERIES 60 PARTS CATALOG
RG.
PART
NO.
TYPE BREAKDOWN
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
ASSY.
SECT.
NAME AND DESCRIPTION
12.8260
23507855
23507856
23S07857
23507858
23507859
2350786Q
23507861
23507854
23512138
23S12139
23512140
23513503
23518918
23519394
23519395
23519396
23519397
23519398
23519399
23519400
23522127
23522128
12.8270
23507863
23507864
23507867
ADDITIVES, SUPPLEMENTAL
COOLANT
SUPPLEM_, _
,M_,I-r_E
ltz GAL.(D_G)
SUPPLEMENt.
COOLANTADDmV_5
GAL.(DD-3000-1;)
SUPR.EMEN_,
COO_.ANT
ADDITIVE55
GAL.(DD-3000.-t5)
SU_
COOLANTADDITIVE1
PT.(_O-200e-P)
SUPPLEMENt,
COOLANT
ADDITIVE
1i2GAL.(DD-2000-HG)
SUPPLEMENT,
CQO-ANTADOfTNE5
GAL.(DD-,,._00-11)
SUPPLEMENt,
COOLANT
ADDmVE55
GAL_(DD-aX_-15)
SU_
COOLANTADDmVE(1
FT.) (DD-3000-P)
PRECH/_GEDCOOLANT(1 GAI-)
CONCENTRATEO
PRECHARGED
COOLANT(55GN-)
CONCENTRATED
PRECHARGED
COOLANT(BULK)
CONCENTRATED
POWERCOOLCOOLANT(BULK)PREBLENDED50to0
FOWERCOOLCOOLANT(55GAL}
PRE-BLENDED
50/50
POWERCOOLPLUSEXTENDEDMFE
COOLANT
55 GAl.(OAC)CONCENTRATED
PWERCOOLPLUSEXTENDED
LIFE
COOLANTBULK(OAC)CONCENTRA'rED
FOWERCOOLPLUSEXTENDEDLIFE
COOLANT
1 GAL(OAC)PRE-BLENDED
50/50
POWERCOOLPLUSEXTENDEDLIFE
COOLANT 1 GAl. (OAC)CONCEN"_RATED
POWERCOOLpLUSEXTENDEDLIFE
COOLANT
55 GAl.(OAC)PREBLENDED
,5_o0
FOWERCOOLpLUSEXTENDEDLIFE
COOLANT
(OAC)PFI_-_LBS_D50/50
POWERCOOLPLUSEXTENDERFOR
USEWffONERCOOLPLU6
POWERCOOLPLUS6000FORM_
RINE/OTHER
WATE_R
ONLYSYSTEMS
POWERCOOLPLUS6000FOR MAPJNFJOTHBR
WA'rl_ ONLYSYSTEMS
CLEANER, COOLANT
SYSTEM
GAL.0DD-20m-HG)
CLF.ANER,COOLANTSYSTEM5 GAL
(DD-_m-'n)
_-FJ_ER, COOLANT
SYSTEM55GAL
(DD-2001-15)
C__EAN_,COOLANT
SYST_ C_nN
PAK)(DD-2015-49)
i
6SPI6_I9809© ]998D_OIT DIESELCO_ON
12.g000A
SUPPLIES[MAINi'__.NANC_
PRODUCTS
TYPE BREAKDOWN
RG.
SERIES
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
60 PARTS
CATALOG
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8280
ADDITIVES, DIESEL FUEL
23507869
ADDITIVES, FUEL 5 GAL
AR
(DD-20_0-11)
23507870
ADDmVES, FUEL 55 GAL
(DD-2020-15)
ADDITIVES, FUEL 1 PZ.(DD-1000-P)
ADDITIVES, FUEL 2 GAL
_DD-1000-11 )
ADDITIVES, FUEL 55 GAL
(DD-1000-15)
23507871
235078"/2
2_S07873
23507888
12.8290
ADDmVES,
FUEL(l PT.){OD-2_0-P)
AR
AR
AFt
• AR i
AR
KIT, COOLANT ANALYSIS
23516921
KIT, POWER TRAC COOLANTANALYSIS
AR :
23519401
POWERTRAC COOLANT
TESTSIRIP
(1 STRIP)
AR
23522774
POWER
TRACCOOLANT
TEST
ga
_I_I0_
STRIPS (BOTTLED 10 S1RIPS)
POWER TRAC COOLANTTEST
SI_IPS _BOI-_ED 50 STRIPS_
AR
r
12.8291
KiT, OIL ANALYSIS
23515823
K_, POWER TRAC IUBE OIL ANALYMS
AR =
23517267
KIT. _
TRAC LUBE OIL EXTRAC-
I AR
23S20989
"nON
KIZ, POWER TRAC LUBE OIL ANALYSiS W/TOTALBASENUMBER
_
AR
KIT, POWER "mAC LUBE OIL ANALYSIS (CANADIANONLY)
_ POWER TRAC OIL EXTRACTION
(CANADIANONLY)
KIT, POWER TRACLUBE OIL ANN.YSIS W/TOTALBASENUMBER
AR
23521982
23521984
23521983
12.8293
AR
AR
KIT, FUEL ANALYSIS
23516922
KIT. POWER TRAC FUEL ANALYSIS
AR
12.8300
23s2o7sa
PANEL, INSTRUMENT
CAGEPANELMEC_NtCAL
_ CAPCLAm'12,'24v
(7.4_)
AR
¢v_907b'7
GAGE PANEL MECHANICAL30' CAP• L,f_Y 12r24V 17.4005)
GAGE PANEL INSTRUMENTCONTROL BLANK (7.4005)
BROOKLET,
I-HOt.E MOUNTING BLACK
23513680
23519833
23513217
23519834
23519835
(7,4oos)
BRACKEZ 2--HOLE MOUNTING RUBGER ('/.4OO5)
BRACKE_,2-HOLE MOUNT1NGBLACK
(7.4OO5)
BRACKET, 3-HOLE MOUNTINGBLACK
:
AR
AR
AR i
AR
AR i
(7.4005)
12.8000A SUPPLIES/MAINTENANCE
_!
PRODUCTS
ssm_
_
© 1998 DETROITDIESELCORPORATION
SERIES 60 PARTS CATALOG
FIG.
PART
NO.
TYPE BREAKDOWN
SUPPUES/MAINTENANCE
PRODUCTS
ASSY.
SECT,
L
NAME AND DESCRIPTION
I
/
12.8310
GAGE,
AMMETER
23519803
GAGE, AMb¢ i E_ 6_0_0
(7.40;5")
B.ACK
_R !
!
___723
GAGE,
AMMETER
_
(7.4ols)
CHROMe
_R ',
i
23519804
GAGE, AM_II;II=H 100-0-100BLACK
_R !
235207.56
GAGE,AMMETER1(X)-.0-100C_ME
(7.4015)
GAGE, AMMc:ICJ.t150.-O-150W/EXTERNALSHUNTCHROME (7.4015)
_
23520733
12.8315
23519792
23520732
23519836
12.8320
!
i
_i
_,R i
[
GAGE, AIR PRESSURE
i
GAGE,AIR PRESSUR_ 150 PSi
SINGLE CHROME (7.4G24)
GAGE, AIR PRESSUF_ 150 PSi
SINGLE BLACK(7.40_4)
IOT,PRESSURETI_BING 6'X I/8"COPPER
AFt i
AR !
]
AR i
GAGE, TACHOMETER
23519774
GAGE, TACH3000RPM W/O HRMI::Tt:H
DDEC COMPATIBLEBLK(USE SENDER 23519819_351ge20 OR 23519821)
7.4060
AR i
i
i
23519775
GAGE, TACH3000RPM W/HP_,_Z_=P_
DDEC COMPATIBLE BLACK (USE
SENDER 2351_I 9,23519620 OR
2351_21) 7.4(]60
AFt i
23519776
GAGF-,TACH300(Y_°M WtHRI__ l _H
DDEC COMPATIBLECPB_OME(USE
SENDER 23519619,235198_0 OFt
23.519_21)7.4060
GAGE, TACH35(]0RPM1".2W/REV
_
MSCH CHROME (7.4060)
GAGE, TACH3300 RPM 1"-2RA_O MECHANCAL (7.4060)
AFt
GAGE, _ACH
MAGNETIC
PICKUP 3_'L 3/4"-16 (7.4180)
S_,ZI_ER, _ACH
HAU. EFF_CT 7/8"-18 (7.4180)
SENDER, SPEEDOrrACH C.-_NERATOR
AR i
!
AR,
23519777
23519819
23519820
23519821
7/8%18 {USE KEY 646_745 OR
64ss746)
(7.4_so)
AR ;
AR
ARI
]
6469745
KEY, .152" _P_EDO_ACH GENERA"/OR
AR i
64_746
KEY,.187" SPEEDO/TACHGENERATOR
AR !
[
4__f_rn_
s_ec_ _ ct_n_e v,_c_ no_e. A_r_t_sreser_
I_P151 f_l_© 1998DETROIT Vllr.31:.LC_N
12.8000A
SUPPLIES/MA]_qTENANCE
PRODUCTS
-"
TYPEBREAKDOWN
RG.
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
PART
NO.
SERIES60 PARTSCATALOG
A
ASSY.
SECT.
NAME AND DESCRIPTION
12.8330
GAGE,OIL PRESSURE-
23519790
GAGE. OIL PRESSURE 100 PSI MECHANICAL BLACK(7.4070)
GAGE. OiL PRESSURE 100 PSI MECHANICAL CHROME (7.4070)
GAGE. OIL PRESSURE 150 PSi MECHANICAL BLACK(7.4O70)
GAGE, OIL PRESSURE 150 PSI MECHAN_CALCHROME (7.4070)
GAGE, OIL PRESSURE 80 PSI 12V
OHM CHROME (USE SENDER
23511477.23512594,23512979.23513978
ENGINE
23520731
23519791
23520721
23520744
235197¢JB
GAGE.OIL PRESSURE 100 PSI 12V
)10-180 OHM BLACK{USE SENDER
AR
AR
AR
AR
AR
AR
zz51_,26)0'.4o7o)
I
23519799
GAGE.OIL PRESSURE 150 PSI 12V
10-180 OHM BLACK (USE SENDER
I AR
i
23511477
SENDER,OIL
PRESS 80PSI,
23519827)
(7.4070)
1/B-27NP'T,DUAL STATION (7.4O70)
SENDER,OIL PRESS
80PS1.1/8-27RFT.STAND/kRDC_VROUND
I AR
SENDER. OIL PRESSURE ELECT 80
PSi FLTING GRD DUAL (7.4070)
SENDER.OIL PRESSURE
80PS1,114"-18NPT,
FLOATING GRD
(7.4O70)
SENDER,OIL PRESSURE
AR
23512,594
AR
(7.4o7o)
23512979
23513978
_3519826
(7.4070)
SENDER.OIL PRESSURE
150PSI,1/8-27NPT` STANDARD GRD
(7.4o70)
100PSI,I/8.-27NPT
STANDARD
GRD.
KIT, PRESSURE TUBING
6' X 1/8"
COPPER
23519827
23519836
12.8335
AR
AR
A_R
GAGE,OIL PRESSURETRANSMISSION
23520746
GAGE, TRANS PRESSURE 400 PSI
12V CHROME (USE SENDER
2351"1617.23513980 OR23513981
7.4071
AR
23519800
GAGE, TRANS PRESSURE 400 PSI
12V BLACK(USE SENDER 23511617,
23513980 OR 23513981) 7.4071
GAGE, TRANS PRESSURE 400 PSI
' AR
GAGE,XRANS PRESSURE 400 PS!
MECHANICALBLACK (7.4071)
SENDER. TRANS PRESSURE 400 PSI
1/8"-27 STD GRD (7.4071)
SENDER. TRANS PRESSURE 400PSI
MECHANICALCHROME (7.4O71)
1/8"-27 FLOATINGGRD 17.4071)
AR
SENDER,
I*RANS
PRESSURE400PS[
1/8"27 DUAL
STATION
(7.4071)
KIT, PRESSURE TUBING 6' X 1/8" COPPER
AR i
23._0"/30
23519794
23511617
23513980
23513981
23519836
I AR
/
i
AR
12.8000A SUPPLIES/MAINTENANCEPRODUCTS
SsPlSl9_me
© 1998
oE'reorrDIESEL
CORPO_TIOH
SERIES
60 PARTS
FIG.
CATALOG
PART
NO.
TYPE
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
NAME AND DESCRIPTION
BREAKDOWN
A
ASSY.
SECT. !
!
;
12.8340
GAGE, OIL TEMPERATURE
I
I
=,R I
23520734
GAGE,OIL TEMP 340t:48" CAPILLARY
23520735
GAGE,OILTEMp340F72"CAPILLARY
MECH
CHROME
(7.4077)
GAGE,OIL "[1[MP340F 72" CAPILLARY
MECHANICALBLACK(7.4077)
GAGE"OIL TEMP 340F 96" CAPILLARY
MECHANICALBLACK(7.,40_
GAGE'OIL TEMP340F 144" CAPILLARY
MECHANICALBLACK(7.4077}
GAGE"OIL TEMP 340F 180" CAPILLARY MECH CHROME (7.4077)
GAGE"OIL TEMP340F 360" CAPILLARYMECHCHROME (7.4077)
GAGE, OIL "I_MP300F, 12V {USE
_
2351_4 OR 23519825)
(7.4O7/)
SENDER,OIL
TEMP.
300DEG1/4--18NPT,STANDARD
GROUND (7.4077)
SENDER,OIL
TEMP,
300DEG1/2-14NF[; STANDARD
GROUND (7.4077)
ADAPTOR,3/8"-18 NPT MECHANICAL
GAGE
air ;
I
_tR
ADAPTOR,1/2-14 NIT MECHANICAL
GAGE
AR
23519787
23519788
23519789
23,S20736
23520737
23519797
23519824
23519825
23519830
23519829
12.8345
23519779
23519780
23519781
23519782
23519783
23519784
23519785
23519786
23S20722
23520724
23520725
23520726
23520727
MECHCHROME
(7.4O77)
GAGE, WATER
TEMPERATURE
GAGE,WATERTBdP 265E 18"CAPILLARYMECHANICALBLACK(7.4080)
GAGE,WA'I'ERTEMP 285F, 3O"CAPILLARYMECHANICALBLACK(7.4O8O)
GAGE, WATERTEMP 285F, 48_CAPILLARYMECHANICALBLACK(7A0e0)
GAGE, WAI_R TEMP265F, 72" CAPILLARYMECHAN_CAL
BLACK(7.4O8O)
GAGE, WA'i_R TEMP265F, g6" CAPILLARYMECHANICALBLACK(7.4080)
GAGE, WATERTEMP265F, 144" CAPILLARYMECHAN]CALBLACK(7.4(_0)
GAGE"WA11"RTEMP 265F, 180" CAPtLLARYMECHAMCALBLACK(7.40e0)
GAGE" WATI=RTEMP 265F, 372" CAFILI,ARYMEOt_CJ¢
B.AC_ (7.4O6O)
GAGE" WATERTI_IP 265F, 18"CAPILI.AFffMECH_.C4_ QHP_M E (7.4080)
GAGE, WA'nERTEMP 26&=, 3O"C_PILLARYMECHANICN-CHROME (7.4O8O)
GAGE, WATER"I'EMP2fiSF,48" CAPILLARYMECHAN¢,JU.CHROME (7.4O8O)
GAGE, WATERTEMP 265F, 72" CAPILLARYMECHANICAL CHROME (7.4O8O)
GAGE, WATERTEMP 265F, 120" CAPILLARYMECHANICAL CHROME
i
=_1 !
_R
err
fir
_,R
AIR;
AR
AR :
AR
A_
AIq
AF
AF
AF
AF
AF
AF
AF
A_
A[
M
(7.4080)
23520738
GAGE, WATERTEMP 265F, 144" CAPILLARYMECHANICAL CHROME
AR
(7.4oeo)
23520701
GAGE, WATERTEMP265F, 180"CAPILLARYMECHANICAL CHROME
AR
(7.4O8O)
Aq/ntormaff_stqect to ctumgem_ho_no_e. A//r/,_asre_erved.
esPtstgeos© 199s
D_n_orrDmSELcom_u_oN
12.8000A SUPPI -WS_"
r,V.I_A_NCE
PRODUCTS
TYPE BREAKDOWN
FIG.
SERIES60PARTSCATALOG
12.800OA
SUPPLIES/MAINTENANCE
PRODUCTS
PART
NO.
ASSY.
SECT.
NAME AND DESCRIPTION
23520739
GAGE, WATERTEMP 265E 372* CApI LLARYMECHANICALCHROME
(7.408O)
12.8345
GAGE, WATER
TEMPERATURE (conL)
23519795
GAGE, WATERTEMP 220F 12VUS
OHM RANGE (7.4_)
GAGE, WA_-R TEMP 250f:, 12V(USE
SENDER 23511301,1303,3982,3983OR
_23)7.4080
GAGE, WATERTEMP 250F, 12V
23519796
23520740
(7.4o8o)
23520742
GAGE WATERTEMP 2501,32V RE,3L._TERKrT (7.40_))
SENDER,TEMR 250DEG3,_8"-lSNPT
STANDARD GROUND {74080)
SEND_LTEMP 250DEG, 1/2"-14N_,
STANDARD GROUND (7.44280)
SENDER, T=# 250 [YEG1[¢-18
FLOATING GROUND (7.40_0)
SENDER,TEMP 250DEG,3/8"-18NPT,
DUAL STATION(7.4080)
SENDER, TEMP 250 DEG 1/4"-18
DUALSTAT_ORFLT GRD (7.4080)
ADAPTOR. 3/8-18 NPT MECHANICAL
GAGE
ADAPTOR, 1/2-14 NPT MECHANZCAL
GAGE
23519823
23511303
23513982
23511301
23513983
23519830
23519829
12.8350
GAGE, FUEL VOLUME
23519806
GAGE, FUEl. 0-90 OHM CHROME
(USE SENDER 23519816) (7.4086)
GAGE, FUEL 0-9O OHM SLACK(USE
SENDER 23519816) (7.41_6)
GAGF_FUEL 10-180 OHMCHROME
(USE SENDER 23519B17) (7.4086)
GAGE, FUEL 10-180 OHMBLACK(USE
S_NDER 23519817) (7.4086)
GAGE, _
240-33 OHM CHROME
(USE SENDER 23519818) {7.4086)
GAGE, FUEL 24O-33 OHM BLACK(USE
SENDER 2351_18) (7.41_6)
SENDER, FUEL 6-23 _ ADJUSTABLE
23519809
23519807
23519810
23519808
23519811
23519816
O-9O
OV_4S
(7.4066)
23519817
SENDER,FUEL 6-23" ADJUSTABLE
10-180 OHMS (7.4086)
SENDER,FUEL6-23" ADJUSTABLE
240-33 OHMS (7.408B}
23519818
12.8360
LAMP, INSTRUMENT PANEL
23519828
23519838
BULB,TYPE C 2W (7.4100)
BULB,TYPET-3 1/4, 2.7W WEDGE
BASE (7.4100)
BULB,TYPE T-3 114,3.4WWEDGE
BASE(7.4100)
23519840
12.8365
AR
AR
AR
SOCKET, LAMP INSTRUMENT
PANEL
23519839
SOCKET, BULB T-3 1/4 WEDGEBASE
AR
(7.41o5)
23519841
SOCKL=_,BULB TYPE C (7.4105)
i AR
8920580
SOCKET,BULBTYPE A
t AR
12.8000A
SUPPLIES/MAINTENANCE
PRODUCTS
Atl_-rnation s_je_ to ct_ng_ w_lo_ _
A_r;_ts _o_,_.
6SP161 9809 © 1998 DETROIT DIESELCORPORATION
SERIES
60 PARTS
RG.
CATALOG
PART
NO.
TYPE BREAKDOWN
12.8000A
SUPPUES/MAINTENANCE
PRODUCTS
A :
ASSY.
SECT.
:
Mt i EH, HOUR QUAR'I-Z 9-28V, NON
ILLUMINATED
CHROME(7.4118)
M_: it-H, HOUR QUAR1Z 9-2.8V, NON
¢LUM_ATE0
B..ACK (7.4rla)
AR
i
[
I
!
MI: rEH, HOUR QUAR'i-Z 9-28V, WA+
TERPROOF
(7.4118)
M_ff-H, HOUR QUARTZ M_NIMETER
AIR J
I
AR i
NAME AND DESCRIPTION
12.8370
23519812
23519813
23519814
23519815
GAGE, HOURMETER
AR
9--28V NON tt.LUMtNATED ('/.4118)
L,F
r
12.8375
23519832
GAGE, TURBO BOOST
GAGE, _
BOOST 0-30 PSI
AR
(7.416o)
23519842
23519836
12.8380
23519801
23519802
12.8385
235t
9773
23519819
23519820
23519821
23520374
6469745
6489746
A# _mat_n
su_ecr zoc_z_e
w_out
GAGE,"fURBOBOOST0-30 PSI
BLACK (7.4160)
_
pRESSUR F TUBING 6' X 1/8" COPPER
AR
GAGE, VOLTMETER
GAGE, VOLTMETEH 8.-16V CHROME
(7.4170)
GAGE, VOLTME: I P.H 8-16V BLACK
(7.4170)
GAGE, SPEEDOMETER
GAGE, SPEEDO 0-85 MPH PROGRAMABLE W/[RIP (7".4180)
GAGE, SPEEDO/TACH MAGNETIC
PtCK UP 3.5"1.. 3/4_--16 (7.4160)
SENDER, SPEEDO/TACH HALL EFFECT 7/8"-18 (7A180)
SENDER, SPEEDOKACH GENERATOR
7m'-_8 (7.4180)
SENDER, SP EEDO/TACH GENERATOR
7/8-18 ODO TERM (7.4180)
KEY,.152" SPELcDO/TACH GENERATOR (FOR USE WffH 23519821 OR
23,520374)
KEY, .187" SPEEIX:)/TACH GENERATOR (FOR USE WITH 23519_21 OR
2352O374)
n_,¢e. A# ng_s reserv_
ssPtba
m0s© ]sss
_zrRorr
DI_S_CORPORA_Om
12.8000ASUPPLITc.S/MAII_
I'I_NANCEPRODUCTS
SERIES 60 SERVICE MANUAL
ABSTRACT
This manual provides instruction for servicing on-highway, construction and industrial, generator
set, and marine applications of the Detroit Diesel Series 60 Diesel and Natural Gas-Fueled
Engines.
Specifically a basic overview of each major component and system along with recommendations
for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical
troubleshooting are contained in this manual.
DDEC III/IV troubleshooting concerns are contained in the DDEC III/IV Single ECM
Troubleshooting Guide, 6SE497.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
i
SERIES 60 SERVICE MANUAL
ENGINE EXHAUST
Consider the following before servicing engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
(Rev. 2004)
ii
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
REVISION NOTIFICATION
Modifications to this manual are announced in the form of Service Information
Bulletins. The bulletins include attachment pages and are posted on the World Wide Web
(www.detroitdiesel.com/svc/sibindex.htm).
Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections
containing revisions will have a third line in the page footer (compare Examples 1 and 2).
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
iii
SERIES 60 SERVICE MANUAL
(Rev. 2004)
iv
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
TABLE OF CONTENTS
GENERAL INFORMATION .....................................................................
SCOPE AND USE OF THIS MANUAL .....................................................
CLEARANCE OF NEW PARTS AND WEAR LIMITS ..............................
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES ......................
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES ..................
GENERAL DESCRIPTION ......................................................................
GENERAL SPECIFICATIONS .................................................................
GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE ............
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL ...................
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES
60G ENGINE) ..........................................................................................
REPLACING AND REPAIRING ................................................................
DISASSEMBLY ........................................................................................
CLEANING ...............................................................................................
SAFETY PRECAUTIONS .......................................................................
FLUOROELASTOMER (VITON) CAUTION .............................................
ENGINE VIEWS .......................................................................................
ENGLISH TO METRIC CONVERSION ....................................................
DECIMAL AND METRIC EQUIVALENTS ................................................
SPECIFICATIONS ....................................................................................
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
ENGINE
CYLINDER BLOCK AND CYLINDER LINER ..........................................
CYLINDER HEAD ....................................................................................
VALVE AND INJECTOR OPERATING MECHANISM ..............................
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS .......
ENGINE LIFTER BRACKETS ..................................................................
ROCKER COVER ....................................................................................
CRANKSHAFT ........................................................................................
CRANKSHAFT OIL SEALS .....................................................................
CRANKSHAFT MAIN BEARINGS ...........................................................
GEAR CASE COVER ..............................................................................
GEAR CASE ............................................................................................
CRANKSHAFT VIBRATION DAMPER .....................................................
CRANKSHAFT PULLEY ..........................................................................
FLYWHEEL .............................................................................................
RING GEAR .............................................................................................
FLYWHEEL HOUSING .............................................................................
PISTON AND PISTON RING ...................................................................
FORGED STEEL ONE PIECE PISTON ASSEMBLY AND PISTON
RING ........................................................................................................
PISTON AND CONNECTING ROD ASSEMBLY .....................................
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
1
3
3
4
6
8
13
14
15
18
19
19
20
26
39
40
45
46
48
1-3
1-30
1-64
1-86
1-118
1-126
1-148
1-169
1-190
1-203
1-237
1-269
1-278
1-294
1-304
1-306
1-314
1-337
1-352
v
SERIES 60 SERVICE MANUAL
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.A
CONNECTING ROD ................................................................................
CYLINDER LINER ...................................................................................
GEAR TRAIN AND ENGINE TIMING ......................................................
THRUST PLATE PERIMETER SEAL .......................................................
CAMSHAFT AND CAMSHAFT BEARING ...............................................
CAMSHAFT DRIVE GEAR ......................................................................
ADJUSTABLE IDLER GEAR ASSEMBLY ................................................
BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY .....................
CRANKSHAFT TIMING GEAR AND TIMING WHEEL ............................
ACCESSORY DRIVE ...............................................................................
JAKE BRAKE® .........................................................................................
ADDITIONAL INFORMATION ..................................................................
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
2.28
2.29
2.30
FUEL SYSTEM
DIESEL FUEL SYSTEM OVERVIEW ......................................................
VEHICLE SAFETY FOR THE NATURAL GAS ENGINE .........................
ELECTRONIC UNIT INJECTOR .............................................................
FUEL INJECTOR TUBE AND O-RING ....................................................
N3 ELECTRONIC UNIT INJECTOR ........................................................
FUEL INJECTOR TUBE ..........................................................................
FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB .....................
FUEL PUMP WITH ONE-PIECE DRIVE SHAFT AND HUB ASSEMBLY
FUEL PUMP DRIVE .................................................................................
DIESEL FUEL FILTERS (SPIN-ON) ........................................................
FUEL PRO 380/380E FUEL FILTER SYSTEM ........................................
SEA PRO 150/300 DIESEL FUEL PROCESSOR SYSTEM (MARINE) ..
SEA PRO 152 FUEL FILTER SYSTEM (MARINE ENGINE) ...................
FUEL FILTER TYPE FOR THE SERIES 60G ENGINE ...........................
FUEL COOLER (HEAT EXCHANGER-COOLED MARINE ENGINE) .....
ASSEMBLY FUEL FILTER AND WATER SEPARATOR ...........................
ELECTRONIC ENGINE CONTROL .........................................................
DDEC V ELECTRONIC CONTROL UNIT ................................................
DDEC III/IV ELECTRONIC CONTROL MODULE ....................................
DDEC II ELECTRONIC CONTROL MODULE .........................................
DDEC I .....................................................................................................
PROGRAMMABLE READ-ONLY MEMORY (PROM) DDEC I ................
ELECTRONIC DISTRIBUTOR UNIT DDEC I .........................................
ELECTRONIC FOOT PEDAL ASSEMBLY ..............................................
TURBO BOOST PRESSURE SENSOR ..................................................
AIR INTAKE PRESSURE SENSOR .........................................................
OIL PRESSURE SENSOR .....................................................................
OIL TEMPERATURE SENSOR ..............................................................
AIR TEMPERATURE SENSOR ...............................................................
AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL
SYSTEM ..................................................................................................
COOLANT TEMPERATURE SENSOR ....................................................
SYNCHRONOUS REFERENCE SENSOR .............................................
2.31
2.32
(Rev. 2004)
vi
1-383
1-398
1-413
1-443
1-458
1-510
1-524
1-535
1-549
1-570
1-603
1-663
2-5
2-7
2-11
2-30
2-46
2-60
2-64
2-87
2-110
2-115
2-124
2-131
2-139
2-148
2-157
2-161
2-169
2-171
2-179
2-187
2-199
2-205
2-209
2-213
2-214
2-216
2-219
2-221
2-223
2-227
2-229
2-231
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
2.33
2.34
2.35
2.36
2.37
2.38
2.A
TIMING REFERENCE SENSOR ............................................................ 2-234
COOLANT LEVEL SENSOR .................................................................. 2-236
FUEL PRESSURE SENSOR .................................................................. 2-240
FUEL TEMPERATURE SENSOR ........................................................... 2-243
EXHAUST GAS OXYGEN SENSOR FOR SERIES 60G ENGINES ........ 2-247
EXHAUST TEMPERATURE SENSOR FOR THE SERIES 60G
ENGINES ................................................................................................. 2-251
KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER
MODULE .................................................................................................. 2-252
BAROMETRIC PRESSURE SENSOR FOR THE SERIES 60G ENGINE
WITH HIGH PRESSURE FUEL SYSTEM .............................................. 2-255
OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES 60G
ENGINES ................................................................................................. 2-257
FUEL PRESSURE GAGES FOR THE SERIES 60G ENGINE WITH A
HIGH PRESSURE FUEL SYSTEM ......................................................... 2-263
VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL
GAS ENGINE (HIGH PRESSURE SYSTEM) ......................................... 2-265
HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE ................................................................................................... 2-269
PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV) FOR
SERIES 60G AUTOMOTIVE ENGINES ................................................... 2-271
FUEL MIXER FOR THE SERIES 60G HIGH PRESSURE FUEL SYSTEM
.................................................................................................................. 2-275
FUEL SHUTOFF VALVE FOR SERIES 60G ENGINE WITH HIGH
PRESSURE FUEL SYSTEM ................................................................... 2-278
IMPCO LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE HIGH PRESSURE FUEL SYSTEM .......................................... 2-280
OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL
SYSTEM .................................................................................................. 2-284
LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE ................................................................................................... 2-289
FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM ....... 2-293
VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS
ENGINE (LOW PRESSURE SYSTEM) .................................................. 2-296
ADDITIONAL INFORMATION .................................................................. 2-299
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
LUBRICATION SYSTEM
OVERVIEW OF LUBRICATING SYSTEM ................................................
OIL PUMP ................................................................................................
OIL PRESSURE REGULATOR VALVE ....................................................
OIL PRESSURE RELIEF VALVE .............................................................
OIL FILTER ..............................................................................................
OIL FILTER ADAPTOR ............................................................................
THERMATIC OIL CONTROL VALVE .......................................................
OIL COOLER (1991 AND LATER ENGINES) ..........................................
OIL COOLER (PRE-1991 ENGINES) ......................................................
OIL LEVEL DIPSTICK ASSEMBLY ..........................................................
2.39
2.40
2.41
2.42
2.43
2.44
2.45
2.46
2.47
2.48
2.49
2.50
2.51
2.52
All information subject to change without notice.
3-3
3-8
3-23
3-30
3-36
3-40
3-46
3-53
3-64
3-74
(Rev. 2004)
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vii
SERIES 60 SERVICE MANUAL
3.11
3.12
3.A
OIL PAN ...................................................................................................
VENTILATING SYSTEM ..........................................................................
ADDITIONAL INFORMATION ..................................................................
4
4.1
4.2
4.3
4.4
4.12
4.13
4.A
COOLING SYSTEM
COOLING SYSTEM OVERVIEW .............................................................
WATER PUMP (GEAR CASE MOUNTED - 1991 AND LATER) (GCM) ..
WATER PUMP (FRONT MOUNTED) (FM) ..............................................
CHARGE AIR COOLER RAW WATER PUMP (KEEL-COOLED
COMMERCIAL MARINE) .........................................................................
THERMOSTAT ........................................................................................
COOLANT PRESSURE CONTROL CAP ................................................
ENGINE COOLING FAN ..........................................................................
COOLANT FILTER AND CONDITIONER ................................................
RADIATOR ...............................................................................................
KEEL COOLING SYSTEM (COMMERCIAL MARINE) ............................
HEAT EXCHANGER COOLING SYSTEM (PLEASURE CRAFT
MARINE) ..................................................................................................
HEAT EXCHANGER (PLEASURE CRAFT MARINE) ..............................
JABSCO® ENGINE COOLING RAW WATER PUMP (MARINE) .............
ADDITIONAL INFORMATION ..................................................................
4-110
4-112
4-128
4-143
5
5.1
5.2
5.3
5.4
FUEL, LUBRICATING OIL, AND COOLANT
FUEL ........................................................................................................
LUBRICATING OIL (DIESEL) ..................................................................
LUBRICATING OIL FOR THE SERIES 60G ENGINE .............................
COOLANT ................................................................................................
5-3
5-12
5-19
5-22
6
6.1
6.2
6.3
6.4
6.5
6.9
6.10
6.11
6.12
6.A
AIR INTAKE SYSTEM
AIR INTAKE SYSTEM OVERVIEW ..........................................................
AIR CLEANER .........................................................................................
AIR SEPARATOR .....................................................................................
INTAKE MANIFOLD .................................................................................
CLOSED CRANKCASE BREATHER FOR SERIES 60G AUTOMOTIVE
ENGINES .................................................................................................
TURBOCHARGER (DIESEL) ..................................................................
TURBOCHARGER SERIES 60 GAS ENGINES (GENSET) ...................
TURBOCHARGER SERIES 60 NATURAL GAS (AUTOMOTIVE)
ENGINE ...................................................................................................
RECIRCULATION VALVE FOR SERIES 60G AUTOMOTIVE ENGINE ...
CHARGE AIR COOLER ...........................................................................
THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE .....................
AIR DRYER ..............................................................................................
ADDITIONAL INFORMATION ..................................................................
6-97
6-116
6-118
6-128
6-133
6-135
7
7.1
7.2
EXHAUST SYSTEM
OVERVIEW OF EXHAUST SYSTEM .......................................................
EXHAUST MANIFOLD .............................................................................
7-3
7-6
4.5
4.6
4.7
4.8
4.9
4.10
4.11
6.6
6.7
6.8
(Rev. 2004)
viii
3-79
3-87
3-95
4-3
4-11
4-43
4-72
4-80
4-92
4-96
4-106
4-108
4-109
6-3
6-9
6-11
6-13
6-24
6-26
6-82
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.A
ELECTRICAL EQUIPMENT
OVERVIEW OF ELECTRICAL SYSTEM .................................................
BATTERY CHARGING ALTERNATOR .....................................................
STORAGE BATTERY ...............................................................................
CRANKING MOTOR ................................................................................
TACHOMETER DRIVE .............................................................................
DDEC III/IV ENGINE SENSOR HARNESS .............................................
DDEC II ENGINE SENSOR HARNESS ...................................................
METRI-PACK 150 SERIES CONNECTORS ............................................
MICRO-PACK SERIES CONNECTORS ..................................................
WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS .......
CONNECTOR TOOLS .............................................................................
SPLICING GUIDELINES .........................................................................
ADDITIONAL INFORMATION ..................................................................
8-3
8-4
8-26
8-29
8-35
8-41
8-51
8-57
8-63
8-65
8-69
8-70
8-75
9
9.1
9.2
POWER TAKE-OFF
FRONT MOUNTED POWER TAKE-OFF .................................................
REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY ....................
9-3
9-8
10
10.1
10.2
10.3
10.4
10.A
SPECIAL EQUIPMENT
AIR COMPRESSOR (VEHICLE APPLICATIONS ONLY) ........................
AIR COMPRESSOR DRIVE HUB ............................................................
AIR COMPRESSOR/RAW WATER PUMP DRIVE ASSEMBLY ..............
KIM HOT START STARTING AID SYSTEM (MARINE) ...........................
ADDITIONAL INFORMATION ..................................................................
10-3
10-19
10-24
10-50
10-51
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
OPERATION AND VERIFICATION
PREPARATION FOR A FIRST TIME START ...........................................
STARTING ................................................................................................
RUNNING .................................................................................................
STOPPING ...............................................................................................
OPERATING CONDITIONS .....................................................................
SERIES 60G GENSET ENGINE OPERATING CONDITIONS ................
SERIES 60G AUTOMOTIVE ENGINE OPERATING CONDITIONS ........
ENGINE RUN-IN INSTRUCTIONS ..........................................................
11-3
11-7
11-8
11-11
11-12
11-16
11-18
11-20
12
12.1
12.2
12.3
12.4
ENGINE TUNE-UP
ENGINE TUNE-UP PROCEDURES ........................................................ 12-3
VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE® LASH
ADJUSTMENTS ....................................................................................... 12-5
ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE ... 12-25
VALVE LASH FOR THE SERIES 60G ENGINE ...................................... 12-27
13
13.1
13.2
13.3
13.4
13.5
PREVENTIVE MAINTENANCE
MAINTENANCE OVERVIEW .................................................................. 13-3
DAILY MAINTENANCE - ALL APPLICATIONS ........................................ 13-4
DAILY MAINTENANCE - MARINE APPLICATIONS ................................ 13-5
MAINTENANCE OF MARINE ENGINES ................................................ 13-6
MAINTENANCE OF VEHICLE ENGINES ............................................... 13-11
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
ix
SERIES 60 SERVICE MANUAL
13.6
MAINTENANCE OF ENGINES USED IN STATIONARY AND
INDUSTRIAL APPLICATIONS .................................................................
13.7 MAINTENANCE OF SERIES 60 DIESEL ENGINES FOR GENERATOR
SET ..........................................................................................................
13.8 MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET ..
13.9 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
13.10 PREVENTIVE MAINTENANCE FOR THE SERIES 60G AUTOMOTIVE
ENGINE (CITY TRANSIT COACH) .........................................................
13.11 MAINTENANCE OF SERIES 60G AUTOMOTIVE ENGINES ..................
13.12 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
(WITH HIGH SULFUR FUELS) ................................................................
13.13 DESCRIPTION OF MAINTENANCE ITEMS ...........................................
13.14 AIR SEPARATOR FILTER ELEMENT (MARINE) .....................................
13.15 DETECTING INTERNAL FUEL LEAKS ...................................................
13.16 CLEANING CONTAMINATED LUBRICATION OIL SYSTEM ...................
13-22
13-25
13-27
13-28
13-31
13-37
13-38
13-75
13-79
13-87
14
14.1
14.2
14.3
STORAGE
PREPARING ENGINE FOR STORAGE ................................................... 14-3
RESTORING AN EXTENDED STORAGE ENGINE ................................ 14-10
WINTER STORAGE FOR MARINE ENGINE ......................................... 14-14
15
15.1
15.2
15.3
15.4
15.5
15.6
15.7
IGNITION SYSTEM
OVERVIEW OF IGNITION SYSTEM .......................................................
COIL OVER PLUG IGNITION SYSTEM ..................................................
IGNITION BOOT ASSEMBLY ..................................................................
IGNITER MODULE .................................................................................
IGNITER MODULE BRACKET ................................................................
IGNITION COIL HARNESS .....................................................................
SPARK PLUGS .......................................................................................
16
16.1
16.2
16.3
16.5
16.6
16.7
MISFIRING CYLINDER
POOR VEHICLE GROUND .....................................................................
AERATED FUEL .....................................................................................
IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ......................................................................................
IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ..................................
FAULTY FUEL INJECTOR .......................................................................
FAULTY ELECTRONIC CONTROL MODULE .........................................
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................
17
17.1
17.2
17.3
17.4
17.5
17.6
17.7
STARTING DIFFICULTY (ENGINE ROTATES)
ELECTRONIC CONTROL MODULE WIRING HARNESS ...................... 17-3
EMPTY FUEL TANK ................................................................................ 17-6
LOW BATTERY VOLTAGE ....................................................................... 17-7
CORRODED OR DAMAGED BATTERY TERMINALS ............................ 17-9
DEFECTIVE MAGNETIC SWITCH .......................................................... 17-10
DEFECTIVE STARTER ............................................................................ 17-13
LOW CRANKING SPEED ........................................................................ 17-15
16.4
x
13-16
(Rev. 2004)
15-3
15-4
15-9
15-10
15-11
15-12
15-16
16-3
16-5
16-7
16-12
16-24
16-26
16-28
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
17.8 FUEL SUPPLY VALVE .............................................................................
17.9 PLUGGED FUEL FILTER(S) ....................................................................
17.10 FUEL PUMP ............................................................................................
17.11 AERATED FUEL .....................................................................................
17.12 RESTRICTIVE AIR FILTER .....................................................................
17.13 LOW COMPRESSION ............................................................................
17-17
17-19
17-21
17-23
17-25
17-27
18
18.1
18.2
18.3
18.4
NO START (ENGINE WILL NOT ROTATE)
DISCHARGED BATTERY ........................................................................ 18-3
DEFECTIVE MAGNETIC SWITCH .......................................................... 18-5
DEFECTIVE STARTER ............................................................................ 18-8
INTERNAL ENGINE DAMAGE ................................................................ 18-10
19
19.1
19.2
19.3
19.4
19.5
19.6
EXCESSIVE OIL CONSUMPTION
MISCALIBRATED DIPSTICK ................................................................... 19-3
EXTERNAL OIL LEAKS ........................................................................... 19-4
LEAKING OIL COOLER CORE ............................................................... 19-6
DEFECTIVE AIR COMPRESSOR ........................................................... 19-8
DEFECTIVE TURBOCHARGER ............................................................. 19-10
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ 19-11
20
20.1
20.2
20.3
20.4
EXCESSIVE CRANKCASE PRESSURE
OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER .........
DEFECTIVE AIR COMPRESSOR ...........................................................
DEFECTIVE TURBOCHARGER .............................................................
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................
21
21.1
21.2
21.3
21.4
21.5
21.6
EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
IMPROPER GRADE OF FUEL OIL ......................................................... 21-3
RESTRICTED AIR CLEANER ELEMENT ............................................... 21-5
RESTRICTED OR CRACKED CHARGE AIR COOLER .......................... 21-7
FAULTY EXHAUST SYSTEM ................................................................... 21-9
FAULTY FUEL INJECTOR ....................................................................... 21-11
DEFECTIVE TURBOCHARGER ............................................................. 21-13
22
22.1
22.2
EXCESSIVE BLUE SMOKE
DEFECTIVE TURBOCHARGER .............................................................
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................
23
23.1
23.2
23.3
23.4
EXCESSIVE WHITE SMOKE
IMPROPER GRADE OF FUEL ................................................................ 23-3
DEFECTIVE FUEL PUMP ....................................................................... 23-5
AERATED FUEL ..................................................................................... 23-7
IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ...................................................................................... 23-9
IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS .................................. 23-11
FAULTY FUEL INJECTOR ....................................................................... 23-13
FAULTY ELECTRONIC CONTROL MODULE ......................................... 23-14
23.5
23.6
23.7
All information subject to change without notice.
20-3
20-5
20-7
20-8
22-3
22-6
(Rev. 2004)
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xi
SERIES 60 SERVICE MANUAL
24
24.1
24.2
24.3
24.4
24.5
24.6
25
25.1
25.2
25.3
25.4
25.5
25.6
25.7
25.8
25.9
ROUGH RUNNING OR STALLING
LOW BATTERY VOLTAGE ....................................................................... 24-3
AERATED FUEL OIL ................................................................................ 24-5
INSUFFICIENT FUEL OIL FLOW ............................................................ 24-6
HIGH FUEL OIL TEMPERATURE RETURN ........................................... 24-8
IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ...................................................................................... 24-11
LOW COMPRESSION PRESSURE ........................................................ 24-13
LACK OF POWER
AERATED FUEL .....................................................................................
HIGH FUEL PRESSURE .........................................................................
HIGH FUEL OIL TEMPERATURE RETURN ...........................................
RESTRICTED AIR CLEANER ELEMENT ...............................................
RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
INTAKE MANIFOLD .................................................................................
FAULTY EXHAUST SYSTEM ...................................................................
HIGH INLET AIR TEMPERATURE ..........................................................
HIGH ALTITUDE OPERATION ................................................................
INCORRECT CAMSHAFT TIMING .........................................................
25-3
25-5
25-9
25-11
25-13
25-15
25-17
25-19
25-21
26
26.1
26.2
26.3
26.4
26.5
26.6
LOW OIL PRESSURE
IMPROPER ENGINE OIL LEVEL ............................................................ 26-3
IMPROPER LUBRICATING OIL VISCOSITY .......................................... 26-5
LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT
26-7
FAULTY OIL PRESSURE GAUGE SENSOR ........................................... 26-9
OIL PRESSURE GAUGE LINE OBSTRUCTED ...................................... 26-11
ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES
ONLY) ....................................................................................................... 26-13
26.7 RESTRICTED OIL COOLER ................................................................... 26-15
26.8 NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR
VALVE ...................................................................................................... 26-17
26.9 DEFECTIVE BYPASS VALVE .................................................................. 26-19
26.10 DEFECTIVE PRESSURE RELIEF VALVE ............................................... 26-20
26.11 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY ........ 26-22
26.12 DEFECTIVE CRANKSHAFT MAIN BEARING SHELLS .......................... 26-24
26.13 DEFECTIVE OIL PUMP ASSEMBLY ....................................................... 26-26
27
27.1
27.2
27.3
27.4
27.5
27.6
27.7
27.8
27.9
HIGH ENGINE COOLANT TEMPERATURE
IMPROPER ENGINE COOLANT LEVEL .................................................
INSUFFICIENT RADIATOR AIR CIRCULATION .....................................
FAULTY PRESSURE CONTROL CAP .....................................................
DEFECTIVE COOLANT HOSES .............................................................
FAN BELTS ARE INCORRECTLY ADJUSTED ........................................
INOPERATIVE THERMO-MODULATED FAN ..........................................
FAULTY THERMOSTATS ........................................................................
FAULTY WATER PUMP ............................................................................
COMBUSTION GASES IN COOLANT ....................................................
(Rev. 2004)
xii
27-3
27-5
27-7
27-9
27-11
27-13
27-15
27-17
27-19
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
27.10 ABNORMAL RADIATOR COOLANT FLOW ............................................ 27-21
28
28.1
28.2
LOW COOLANT TEMPERATURE
FAULTY THERMOSTATS ........................................................................
INSUFFICIENT RADIATOR AIR CIRCULATION .....................................
28-3
28-5
29
29.1
POOR FUEL ECONOMY
PROBABLE CAUSE #1 ............................................................................
29-3
INDEX .................................................................................................
All information subject to change without notice.
Index-1
(Rev. 2004)
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xiii
SERIES 60 SERVICE MANUAL
(Rev. 2004)
xiv
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
GENERAL INFORMATION
Section
Page
SCOPE AND USE OF THIS MANUAL .......................................................
3
CLEARANCE OF NEW PARTS AND WEAR LIMITS .................................
3
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES .........................
4
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES .....................
6
GENERAL DESCRIPTION .........................................................................
8
GENERAL SPECIFICATIONS ....................................................................
13
GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE ...............
14
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL .....................
15
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES 60G
ENGINE) ..............................................................................................
18
REPLACING AND REPAIRING ..................................................................
19
DISASSEMBLY ...........................................................................................
19
CLEANING ..................................................................................................
20
SAFETY PRECAUTIONS ..........................................................................
26
FLUOROELASTOMER (VITON) CAUTION ................................................
39
ENGINE VIEWS ..........................................................................................
40
ENGLISH TO METRIC CONVERSION ......................................................
45
DECIMAL AND METRIC EQUIVALENTS ...................................................
46
SPECIFICATIONS ......................................................................................
48
SERIES 60 SERVICE MANUAL
2
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
SCOPE AND USE OF THIS MANUAL
This manual contains complete instructions on operation, adjustment (tune-up), preventive
maintenance, and repair (including complete overhaul) for the Series 60 Inline Diesel Engines.
This manual was written primarily for persons servicing and overhauling the engine. In addition,
this manual contains all of the instructions essential to the operators and users. Basic maintenance
and overhaul procedures are common to all Series 60 Engines, and apply to all engine models.
This manual is divided into numbered sections. Section one covers the engine (less major
assemblies). The following sections cover a complete system such as the fuel system, lubrication
system, or air system. Each section is divided into subsections which contain complete
maintenance and operating instructions for a specific engine subassembly. Each section begins
with a table of contents. Pages and illustrations are numbered consecutively within each section.
Information can be located by using the table of contents at the front of the manual or the table of
contents at the beginning of each section. Information on specific subassemblies or accessories
within the major section is listed immediately following the section title.
CLEARANCE OF NEW PARTS AND WEAR LIMITS
New parts clearances apply only when all new parts are used at the point where the various
specifications apply. This also applies to references within the text of the manual. The column
entitled "Limits" must be qualified by the judgement of personnel responsible for installing new
parts. For additional information, refer to the section entitled "Inspection" within this section.
Refer to section ADDITIONAL INFORMATION, "Table of Specifications, New Clearances,
and Wear Limits" under "Specifications", for a listing of clearances of new parts and wear
limits on used parts.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
3
SERIES 60 SERVICE MANUAL
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES
The diesel engine is an internal combustion engine, in which the energy of burning fuel is
converted into energy to work the cylinder of the engine. In the diesel engine, air alone
is compressed in the cylinder, raising its temperature significantly. After the air has been
compressed, a charge of fuel is sprayed into the cylinder and ignition is accomplished by the
heat of compression. The four piston strokes of the cycle occur in the following order: intake,
compression, power and exhaust. See Figure 1.
Figure 1
The Four Stroke Cycle (Diesel)
Intake Stroke
During the intake stroke, the piston travels downward, the intake valves are open, and the exhaust
valves are closed. The down stroke of the piston facilitates air from the intake manifold to enter
the cylinder through the open intake valve. The turbocharger, by increasing the air pressure in the
engine intake manifold, assures a full charge of air is available for the cylinder.
The intake charge consists of air only with no fuel mixture.
4
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
Compression Stroke
At the end of the intake stroke, the intake valves close and the piston starts upward on the
compression stroke. The exhaust valves remain closed.
At the end of the compression stroke, the air in the combustion chamber has been compressed by
the piston to occupy a space about one-fifteenth as great in volume as it occupied at the beginning
of the stroke. Thus, the compression ratio is 15:1.
Compressing the air into a small space causes the temperature of that air to rise. Near the end of
the compression stroke, the pressure of the air above the piston is approximately 3445 to 4134
kPa (500 to 600 lb/in.2) and the temperature of that air is approximately 538 C (1000 F). During
the last part of the compression stroke and the early part of the power stroke, a small metered
charge of fuel is injected into the combustion chamber.
Almost immediately after the fuel charge is injected into the combustion chamber, the fuel is
ignited by the hot air and starts to burn, beginning the power stroke.
Power Stroke
During the power stroke, the piston travels downward and all intake and exhaust valves are closed.
As the fuel is added and burns, the gases get hotter, the pressure increases, pushing the piston
downward and adding to crankshaft rotation.
Exhaust Stroke
During the exhaust stroke, the intake valves are closed; the exhaust valves are open, and the
piston is on its up stroke.
The burned gases are forced out of the combustion chamber through the open exhaust valve port
by the upward travel of the piston.
From the preceding description, it is apparent that the proper operation of the engine depends
upon the two separate functions: first, compression for ignition, and second, that fuel be measured
and injected into the compressed air in the cylinder in the proper quantity and at the proper time.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES
This engine is a four cycle internal combustion engine, in which the energy of burning fuel is
converted into energy to work the cylinder of the engine. However, unlike the diesel engine, a
combustible air and fuel mixture is introduced to the cylinder during the intake stroke. Upon
compression, the temperature of this mixture is increased to a temperature below its auto-ignition
threshold. Combustion occurs through means of a spark plug which ignites the mixture.
See Figure 2 for the four stroke cycle utilized on the natural gas engine.
Figure 2
6
The Four Stroke Cycle (Series 60G Engine)
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Intake Stroke
During the intake stroke, the piston travels downward, the intake valves are open, and the exhaust
valve are closed. The downward stroke of the piston increases the volume in the cylinder and
draws in a fresh air and fuel mixture through the intake valves.
Compression Stroke
At the end of the intake stroke, the intake valves close and the piston starts upward on the
compression stroke. The exhaust valves remain closed.
At the end of the compression stroke, the air-fuel mixture in the combustion chamber has been
compressed by the piston to occupy a space about one-tenth as great in volume as it occupied
at the beginning the stroke. Thus, the compression ratio is 10:1. This act of compression
dramatically increases the temperature of the air-fuel mixture, to a temperature below its
auto-ignition threshold. It is a timed, externally supplied ignition through the spark plug that
actually causes ignition to the mixture. The timed spark is introduced to the cylinder near the end
of the compression stroke, which initiates combustion and begins the power stroke.
Power Stroke
During the power stroke, the piston travels downward and all intake and exhaust valves are closed.
As the throttle is opened to introduce a greater charge of air-fuel mixture to the cylinders, the
increasing pressure of combustion against the pistons adds to crankshaft rotation.
Exhaust Stroke
During the exhaust stroke, the intake valves are closed, the exhaust valves are open, and the
piston is on its up stroke.
The burning gases are forced out of the combustion chamber through the open exhaust valve port
by the upward travel of the piston.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
GENERAL DESCRIPTION
The Series 60® Diesel Engine described in this manual is a four-stroke cycle, high speed, diesel
engine.
It uses an inline cast iron block and has a cast iron cylinder head that contains a single overhead
camshaft. The camshaft actuates all the valves (two intake, two exhaust per cylinder), and
operates the fuel injectors. The vertically aligned gear train, located at the front end of the
engine in a gear case, contains drive gears for the lubricating oil pump, crankshaft, camshaft, air
compressor drive, fuel pump drive, water pump and alternator accessory drives.
Each current engine is equipped with dual full-flow oil filters, an oil cooler, one or two fuel oil
filters, a turbocharger and an electronic engine control system.
Full pressure lubrication is supplied to all main, connecting, camshaft and rocker assembly
bearings and to other moving parts. A gear-type pump draws oil from the oil pan through a screen
and delivers it to the oil filters. From the filter, a small portion of the oil is delivered directly to
the turbocharger by an external oil line. The remainder of the oil flows to the oil cooler, or
bypasses the cooler, and then enters a longitudinal oil gallery in the cylinder block where the
supply divides. Part of the oil goes to the cylinder head where it feeds the camshaft bearings
and rocker assemblies. The remainder of the oil goes to the main bearings and connecting rod
bearings via the drilled oil passages in the crankshaft. Drilled passages in the connecting rod feed
oil to the piston pin and the inner surface of the piston crown.
Coolant is circulated through the engine by a centrifugal-type water pump. The cooling system,
including the radiator, is a closed system. Heat is removed from the coolant by the radiator.
Control of the engine temperature is accomplished by thermostats that regulate the flow of the
coolant within the cooling system.
Fuel is drawn from the supply tank through the primary fuel filter by a gear-type fuel pump. From
there, the fuel is forced through the secondary fuel filter and into the fuel inlet in the cylinder head
and to the injectors. Excess fuel is returned, through a restricted fitting, to the supply tank through
the outlet connecting line. Since the fuel is constantly circulating through the injectors, it serves
to cool the injectors and to carry off any air in the fuel system. Air separators are available, as
optional equipment.
Air is supplied by the turbocharger to the intake manifold and into the engine cylinders after
passing through an air-to-air charge air cooler mounted ahead of the cooling system radiator. The
charge air cooler cools the pressurized intake air charge coming from the turbocharger before it
enters the intake manifold.
Engine starting may be provided by an electric or air starting motor energized by a storage battery
or air pressure storage system. A battery charging alternator, with a suitable voltage regulator,
serves to keep the battery charged.
The Series 60 diesel engine was designed to be electronically controlled. The Detroit Diesel
Electronic Control (DDEC) system has evolved with the product.
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(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
DDEC I
DDEC I controls the timing and amount of fuel injected into each cylinder. The system also
monitors several engine functions using various sensors that send electrical signals to the main
Electronic Control Module (ECM). See Figure 3. The ECM uses this information to send a
command pulse to the Electronic Distributor Unit (EDU). The EDU functions as the high current
switching unit for actuation of the Electronic Unit Injector (EUI) solenoids. The ECM also has the
ability to limit or shut down the engine completely (depending on option selection) in the case of
damaging engine conditions, such as low oil pressure, low coolant level, or high oil temperature.
Figure 3
Schematic Diagram of DDEC I
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
DDEC II
DDEC II also controls the timing and amount of fuel injected into each cylinder. The system also
monitors several engine sensors that send electrical signals to the main ECM. See Figure 4.
Unlike DDEC I, the DDEC II ECM uses this information to actuate the EUI solenoids. DDEC
II incorporates all of the control electronics into one engine mounted ECM instead of the ECM
and EDU that are required in DDEC I. The ECM also has the ability to limit or shut down the
engine completely (depending on option selection) in the case of damaging engine conditions,
such as low oil pressure, low coolant level, or high oil temperature.
Figure 4
10
Schematic Diagram of DDEC II
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
DDEC III/IV
The DDEC III/IV ECM receives electronic inputs from sensors on the engine and vehicle, and
uses the information to control engine operation. It computes fuel timing and fuel quantity based
upon predetermined calibration tables in its memory.
Fuel is delivered to the cylinders by the EUIs, which are cam-driven to provide the mechanical
input for pressurization of the fuel. The ECM controls solenoid operated valves in the EUIs to
provide precise fuel delivery. See Figure 5.
Figure 5
Schematic Diagram of DDEC III/IV
Portable equipment facilitates access to diagnostic capabilities of DDEC III/IV's. The Diagnostic
Data Reader (DDR) requests and receives engine data and diagnostic codes. This equipment
provides many unique capabilities including cylinder cutout, printer output, and data snapshot.
The DDR also provides limited programming capability.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
DDEC III/IV (Series 60G Engine)
The DDEC III/IV ECM receives electronic inputs from sensors on the engine and vehicle, and
uses the information to control engine operation.
Fuel is controlled by DDEC. See Figure 6.
Figure 6
Schematic Diagram of DDEC III/IV (Series 60G Engine)
Portable equipment facilitates access to diagnostic capabilities of DDEC III/IV's. The Diagnostic
Data Reader (DDR) requests and receives engine data and diagnostic codes. This equipment
provides many unique capabilities including cylinder cutout, printer output, and data snapshot.
The DDR also provides limited programming capability.
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(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
GENERAL SPECIFICATIONS
The general specifications for the Series 60 Engine are listed in Table 1. See Figure 7 for the
cylinder designation and firing order.
General Specifications
11.1L Family
12.7L Family
14L Family
Total Displacement (L)
11.1
12.7
14.0
Total Displacement (in.3)
677
775
855
Type
4-cycle
4-cycle
4-cycle
Number of Cylinders
6
6
6
Bore (in.)
5.12
5.12
5.24
Bore (mm)
130
130
133
Stroke (in.)
5.47
6.30
6.61
Stroke (mm)
139
160
168
Compression Ratio
16.0:1
15.0:1 or 16.5:1
15.0:1 or 16.5:1
Number of Main Bearings
7
7
7
Table 1
Figure 7
Specifications for the Series 60 Engine
Cylinder Designation and Firing Order
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE
The general specifications for the Series 60G Engine are listed in Table 2. See Figure 8 for
cylinder designation and firing order.
Table 2
Figure 8
14
General Description
Specification
Total Displacement (L)
12.7
Total Displacement (in.3)
775
Type
Four-cycle
Number of Cylinders
6
Bore (in.)
5.12
Bore (mm)
130
Stroke (in.)
6.30
Stroke (mm)
160
Compression Ratio
10:1
Number of Main Bearings
7
General Specifications for the Series 60G Engine
Cylinder Designation and Firing Order for the Series 60G Engine
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL
The engine serial and model numbers are stamped on the cylinder block. See Figure 9. A guide to
the meaning of the model number digits is listed in Table 3.
Figure 9
Location of Engine Serial and Model Number on Block
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Table 3
Digit
Value
Meaning
1
6
Series 60 Engine
2 & 3
06
Six Cylinders
4
2
Marine Application
4
3
Industrial Application
4
5
Generator Application
4
7
Automotive Application
5
W, S, E, L
11.1 L Displacement
5
G, T, M
12.7 L - Standard
5
P, B
12.7 L - Premium
5
F, H
14 L Displacement
6
T
DDEC I Engine Control
6
U
DDEC II Engine Control
6
K
DDEC III/IV Engine Control
7 & 8
28
1991 and later Coach
7 & 8
32
Underground Mining
7 & 8
40
Pre-1991 Engine
7 & 8
60
1991 and later On-Highway Truck
Model Number Description for Series 60 Engine
For example, 6067-WK60 represents an 11.1 liter Series 60 engine that is controlled with DDEC
III/IV electronics to be used in a 1991 or later truck.
Option labels attached to the valve rocker cover contain the engine serial and model numbers and
list any optional equipment used on the engine. See Figure 10.
With any order for parts, the engine model number with serial number should be given. In
addition, if a type number is shown on the option plate covering the equipment required, this
number should also be included on the parts order.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
All groups or parts used on a unit are standard for the engine model unless otherwise listed
on the option plate.
Figure 10
Rocker Cover with Option Label
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES 60G
ENGINE)
The engine serial and model numbers are stamped on the cylinder block. See Figure 11. A guide
to the meaning of the serial number digits is listed in Table 4.
Figure 11
Table 4
18
Location of Engine Serial and Model Number on Block (Series 60G
Engine)
Digit
Value
Meaning
1
6
Series 60 Engine
2 & 3
06
Six Cylinders
4
3 / 7
Generator Application / Automotive
5
G / T
12.7 L Displacement
6
K
DDEC III / DDEC IV
7
G
Alternate Fuel Engine
8
5 / 8
Customer Designation
Model Number Description for Series 60G Engine
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
REPLACING AND REPAIRING
In many cases, a technician is justified in replacing parts with new material rather than attempting
repair. However, there are times when a slight amount of reworking or reconditioning may save a
customer considerable added expense. Exchange assemblies such as injectors, fuel pumps, water
pumps and turbochargers are desirable service items.
Various factors such as the type of operation of the engine, hours in service and the next overhaul
period must be considered when determining whether new parts are installed or used parts are
reconditioned to provide trouble-free operation.
For convenience and logical order in disassembly and assembly, the various subassemblies and
other related parts mounted on the cylinder block will be treated as separate items in the various
sections of the manual.
DISASSEMBLY
A technician can be severely injured if caught in pulleys, belts or the fan of an engine that is
accidentally started. To avoid such a misfortune, take the following precautions before starting to
work on an engine.
To avoid injury from accidental engine startup while
servicing the engine, disconnect/disable the starting
system.
To avoid injury from the sudden release of a high-pressure
hose connection, wear a face shield or goggles. Bleed the
air from the air starter system before disconnecting the air
supply hose.
Before any major disassembly, the engine must be drained of lubricating oil, coolant and fuel.
To perform a major overhaul or other extensive repairs, the complete engine assembly, after
removal from the engine base and drive mechanism, should be mounted on an engine overhaul
stand; then the various subassemblies should be removed from the engine. When only a few items
need replacement, it is not always necessary to mount the engine on an overhaul stand.
Parts removed from an individual engine should be kept together so they will be available for
inspection and assembly. Those items having machined faces, which might be easily damaged by
steel or concrete, should be stored on suitable wooden racks or blocks, or a parts dolly.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
CLEANING
Before removing any of the subassemblies from the engine (but after removal of the electrical
equipment), the exterior of the engine should be thoroughly cleaned.
NOTICE:
The Series 60 engine is equipped with various sensors and other
electronic components which may be damaged if subjected to
the high temperatures in a solvent tank. Do not immerse any
electrical components in a solvent tank. Care should be taken
to ensure that all electronic components are removed from the
various engine assemblies before they are immersed in a solvent
tank. Refer to section 8for a description of these components.
Then, after each subassembly is removed and disassembled, the individual parts should be
cleaned. Thorough cleaning of each part is absolutely necessary before it can be satisfactorily
inspected. Various items of equipment needed for general cleaning are listed below.
The cleaning procedure used for all ordinary cast iron parts is the same as the following cylinder
block cleaning procedure. Any special cleaning procedures will be mentioned when required.
Remove cylinder liners before putting the block in cleaning or descaling baths, to avoid trapping
cleaning agents in block liner seating bores.
After stripping and before removing the cylinder block from the overhaul stand for cleaning and
inspection, install the two metric eye bolts into head bolt holes at each end of the cylinder block.
Remove all oil and water gallery and weep hole plugs to allow the cleaning solution to enter the
inside of the oil and water passages.
1. Using two metric eye bolts installed in the head bolt holes at opposite ends of the block,
and with a suitable lifting device and spreader bar, immerse and agitate the block in a hot
bath of a commercial, heavy-duty alkaline solution.
2. Wash the block in hot water or steam clean it to remove the alkaline solution.
3. If the water jackets are heavily scaled, proceed as follows:
20
[a]
Agitate the block in a bath of inhibited phosphoric acid.
[b]
Allow the block to remain in the acid bath until the bubbling action stops
(approximately 30 minutes).
[c]
Lift the block, drain it and immerse it again in the same acid solution for 10 more
minutes. Repeat until all scale is removed from the water jacket area.
[d]
Rinse the block in clear, hot water to remove the acid solution.
[e]
Neutralize the acid that may cling to the casting by immersing the block in an
alkaline bath.
[f]
Wash the block in clean water or steam clean it.
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
4. Dry the cylinder block with compressed air.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
5. Blow out all of the bolt holes and passages with compressed air.
NOTE:
The above cleaning procedure may be used on all ordinary cast iron and steel parts for
the engine. Aluminum parts, such as flywheel housing, air intake manifold, oil filter
adaptor and the camshaft gear access cover should NOT be cleaned in this manner.
Mention will be made of special procedures when necessary.
6. Be certain that all water passages and oil galleries have been thoroughly cleaned. After
the cylinder block has been thoroughly cleaned and dried, install weep hole plugs and
precoated pipe plugs. Install new cup plugs using a coating of good grade non-hardening
sealant such as Loctite® 620 or equivalent.
Loctite® is a registered trademark of The Loctite Corporation.
Steam Cleaning
A steam cleaner is a necessary item in a large shop and is useful for removing heavy accumulations
of grease and dirt from the exterior of the engine and its subassemblies.
Solvent Tank Cleaner
Chlorinated solvents such as 1,1,1 trichloroethane have been identified by the EPA
(Environmental Protection Agency) as possessing ozone-depleting properties. Special procedures
have been developed for the handling and proper disposal of these chemicals. For environmental
considerations, Detroit Diesel has replaced 1,1,1 trichloroethane with Tech Solv 340 branded
solvent.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Tech Solv 340 is a petroleum-based solvent that contains no chlorinated or fluorinated
compounds, has a controlled evaporation rate, leaves no residue, is odorless, has a high flash
point, and provides outstanding cleaning. To enhance its cleaning and drying properties, it may
be heated to 52 C (125 F). Spills can be cleaned up with commercially available oil absorbents,
and conventional waste treatment methods for petroleum-based products can be used when
disposing of this product.
Detroit Diesel believes that a prudent environmental approach to the use of 1,1,1 trichloroethane
should be taken. Therefore, Detroit Diesel recommends replacing 1,1,1 trichloroethane with Tech
Solv 340 branded solvent wherever the former solvent was used.
Tech Solv 340 is manufactured by and available from the following supplier:
Chemical Technologies, Inc.
1610 Clara Street
Jackson, MI 49203
Telephone: 800-688-8262
FAX: 517-782-2448
We believe this source and their Tech Solv 340 solvent to be reliable. There may be other
manufacturers of solvents that replace 1,1,1 trichloroethane. Detroit Diesel does not endorse,
indicate any preference for, or assume any responsibility for the solvents from these firms or for
any such products that may be available from other sources.
Solvent Tank Cleaning
A tank of sufficient size to accommodate the largest part that will require cleaning (usually the
cylinder block) should be provided and provisions made for heating the cleaning solution.
To avoid injury, wear a face shield or goggles.
Fill the tank with a commercial heavy-duty solvent, such as Tech Solv 340, that is heated to
52 C (125 F). Lower large parts directly into the tank with a hoist. Place small parts in a wire
mesh basket and lower them into the tank. Immerse the parts long enough to loosen all of the
grease and dirt.
Aluminum or plastic parts such as the flywheel housing, fuel pump drive, air intake manifold,
oil filter adaptor, camshaft gear access cover, oil pan or rocker covers, should not be cleaned
in this manner.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Rinsing Bath
Provide another tank of similar size containing hot water for rinsing the parts.
Drying
Parts may be dried with compressed air.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
The heat from the hot tanks will quite frequently complete drying of the parts without the use of
compressed air.
Rust Preventive
If parts are not to be used immediately after cleaning, dip them in a suitable rust preventive
compound. The rust preventive compound should be removed before installing the parts in
an engine.
Gasket Eliminator Removal
The gasket eliminator used on numerous mating surface joints in the Series 60 engine results in
a very thin film that must be removed from both surfaces prior to reassembly. As many of the
surfaces are aluminum and/or dimensionally critical, conventional scraping methods, or the use of
emery cloth for removing gasket eliminator is not recommended.
Four-inch, 3M Scotch-Brite® Surface Conditioning Discs, used with an electric or air powered
hand drill (with a speed of 15,000-18,000 r/min), have proven successful in removing the gasket
eliminator without damaging the mating surfaces of engine parts. See Figure 12.
Scotch-Brite® is a registered trademark of the 3M Corporation.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Figure 12
Gasket Eliminator Removal
A coarse pad, is suitable for steel surfaces. A medium pad is recommended for aluminum surfaces.
The pads are easily interchangeable. See Figure 13.
Figure 13
24
Scotch-Brite Surface Conditioning Disc Installation
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Inspection
The purpose of parts inspection is to determine which parts can be used and which must be
replaced. Although the engine overhaul specifications given throughout the text will aid in
determining which parts should be replaced, considerable judgment must be exercised by the
inspector. The guiding factors in determining the usability of worn parts, that are otherwise in
good condition, is the clearance between the mating parts and the rate of wear on each of the parts.
If it is determined that the rate of wear will maintain the clearances within the specified maximum
allowable until the next overhaul period, the reinstallation of used parts may be justified. Rate of
wear of a part is determined by dividing the amount the part has worn by the hours it has operated
Many service replacement parts are available in various undersize or oversize as well as standard
sizes. Also, service kits for reconditioning certain parts and service sets that include all of the
parts necessary to complete a particular repair job are available.
A complete discussion of the proper methods of precision measuring and inspection are outside
the scope of this manual. However, every shop should be equipped with standard gages, such as
dial bore gages, dial indicators, and inside and outside micrometers.
In addition to measuring the used parts after cleaning, the parts should be carefully inspected for
cracks, scoring, chipping and other detrimental conditions.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
SAFETY PRECAUTIONS
The following safety measures are essential when working on the Series 60 engine.
Exhaust (Start/Run Engine)
Before starting and running an engine, adhere to the following safety precautions:
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
Stands
Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either the
jack or the hoist to carry the load. When lifting an engine, ensure the lifting device is fastened
securely. Ensure the item to be lifted does not exceed the capacity of the lifting device.
Glasses
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when
using tools such as hammers, chisels, pullers or punches.
To avoid injury, wear a face shield or goggles.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Welding
Wear welding goggles and gloves when welding or using an acetylene torch.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
To avoid injury from arc welding, gas welding, or cutting,
wear required safety equipment such as an arc welder’s
face plate or gas welder’s goggles, welding gloves,
protective apron, long sleeve shirt, head protection,
and safety shoes. Always perform welding or cutting
operations in a well-ventilated area.
The gas in
oxygen/acetylene cylinders used in gas welding and
cutting is under high pressure. If a cylinder should fall
due to careless handling, the gage end could strike an
obstruction and fracture, resulting in a gas leak leading to
fire or an explosion. If a cylinder should fall resulting in
the gage end breaking off, the sudden release of cylinder
pressure will turn the cylinder into a dangerous projectile.
Observe the following precautions when using
oxygen/acetylene gas cylinders:
Always wear required safety shoes.
Do not handle tanks in a careless manner or with greasy
gloves or slippery hands.
Use a chain, bracket, or other restraining device at all
times to prevent gas cylinders from falling.
Do not place gas cylinders on their sides, but stand
them upright when in use.
Do not drop, drag, roll, or strike a cylinder forcefully.
Always close valves completely when finished welding
or cutting.
To avoid injury from fire, check for fuel or oil leaks before
welding or carrying an open flame near the engine.
NOTICE:
Use proper shielding around hydraulic lines when welding to
prevent hydraulic line damage.
Ensure that a metal shield separates the acetylene and oxygen that must be chained to a cart.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Work Place
Organize your work area and keep it clean. A fall could result in a serious injury. Eliminate
the possibility of a fall by:
Wiping up oil spills
Keeping tools and parts off the floor
After servicing or adjusting the engine:
Reinstall all safety devices, guards or shields
Ensure that all tools and servicing equipment are removed from the engine
Clothing
Safe work clothing fits and is in good repair. Work shoes are sturdy and rough-soled. Bare feet,
sandals or sneakers are not acceptable foot wear when adjusting and/or servicing an engine. Do
not wear the following when working on an engine:
To avoid injury when working on or near an operating
engine, wear protective clothing, eye protection, and
hearing protection.
Rings
Wrist watches
Loose fitting clothing
Any of these items could catch on moving parts causing serious injury.
Power Tools
Do not use defective portable power tools.
To avoid injury from electrical shock, follow OEM furnished
operating instructions prior to usage.
Check for frayed cords prior to using the tool. Be sure all electric tools are grounded. Defective
electrical equipment can cause severe injury. Improper use of electrical equipment can cause
severe injury.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Air
Recommendations regarding the use of compressed air are indicated throughout the manual.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
Fuel Lines
Remove fuel lines as an assembly. Do not remove fuel lines individually. Avoid getting fuel
injection lines mixed up.
Fluids and Pressure
Be extremely careful when dealing with fluids under pressure.
To avoid injury from penetrating fluids, do not put your
hands in front of fluid under pressure. Fluids under
pressure can penetrate skin and clothing.
Fluids under pressure can have enough force to penetrate the skin. These fluids can infect a minor
cut or opening in the skin. If injured by escaping fluid, see a doctor at once. Serious infection
or reaction can result without immediate medical treatment.
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(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Fuel
Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank
when refueling to avoid the possibility of an electric spark igniting the fuel.
To avoid injury from fire caused by heated diesel-fuel
vapors:
Keep those people who are not directly involved in
servicing away from the engine.
Stop the engine immediately if a fuel leak is detected.
Do not allow open flames or smoke when working on
an operating engine.
Wear adequate protective clothing (face shield,
insulated gloves and apron, etc.).
To prevent a buildup of potentially volatile vapors, keep
the engine area well ventilated during operation.
Diesel fuel is relatively harmless at ambient temperatures.
To avoid injury from possible fuel vapor ignition when
refueling, keep the hose, nozzle, funnel, or container in
contact with the metal opening of the fuel tank. This will
reduce the likelihood of a dangerous spark.
This caution applies to gasoline engines.
The following cautions should be followed when filling a fuel tank:
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
To avoid injury from fire, do not overfill the fuel tank.
To avoid injury from fire, keep all potential ignition sources
away from diesel fuel, open flames, sparks, and electrical
resistance heating elements. Do not smoke when refueling.
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(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Batteries
Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to
do so for some time after receiving a steady charge.
To avoid injury from battery explosion or contact with
battery acid, work in a well-ventilated area, wear protective
clothing, and avoid sparks or flames near the battery.
Always establish correct polarity before connecting cables
to the battery or battery circuit. If you come in contact with
battery acid:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water.
Get medical attention immediately.
Always disconnect the battery cable before working on the electrical system.
To avoid injury from accidental engine startup while
servicing the engine, disconnect/disable the starting
system.
Disconnect the batteries or disable an air starter when working on the engine (except DDEC) to
prevent accidental starting.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Fire
Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher
for the situation.
Cleaning Agent
Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it
releases. Ensure the work area is adequately ventilated. Use protective gloves, goggles or face
shield, and apron.
To avoid injury from harmful vapors or skin contact, do not
use carbon tetrachloride as a cleaning agent.
Exercise caution against burns when using oxalic acid to clean the cooling passages of the engine.
Working on a Running Engine
When working on an engine that is running, accidental contact with the hot exhaust manifold can
cause severe burns.
To avoid injury from unguarded rotating and moving engine
components, check that all protective devices have been
reinstalled after working on the engine.
To avoid injury, use care when working around moving belts
and rotating parts on the engine.
34
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Start Attempts
Avoid excessive injection of ether into the engine during start attempts.
To avoid injury from an explosion of natural gas, the
following precautions must be taken:
Do not smoke when installing or servicing the engine
or fuel system.
Installation or servicing of natural-gas equipment
must only be conducted in well-ventilated, natural gas
compatible areas. Do not install or service equipment
in an enclosed area where ignition sources are present
without first ensuring that an undetected gas leak may
be safely vented without being ignited.
Bleed natural gas lines before installing or servicing
any component connected to the fuel lines.
Natural gas fuel systems are pressurized. Relieve
pressure from any fuel system component prior to
installation or service of that component.
Use a combustible-gas detector. Liquefied natural gas
(LNG) is odorless and cannot be detected by smell.
Compressed Natural gas (CNG) may be odorless and
may not be detected by smell.
Equipment fuel systems are the responsibility of the
Original Equipment Manufacturer (OEM). Equipment
fuel system guidelines must be closely adhered to
when installing or servicing equipment. Refer to OEM
guidelines specifying which maintenance procedures
require venting of fuel lines and fuel tanks.
LNG systems are pressurized and contain extremely
cold (-260 F [-162 C]) fluids. Contact the fuel supplier or
OEM for LNG safety requirements. Contact with LNG
may cause personal injury (freezing).
Vent systems on the equipment should be ducted to a
safe area whenever equipment is in an enclosed area.
Natural gas is highly flammable and explosive and may be
extremely cold (-260 F [-162 C]).
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
NOTICE:
Avoid excessive injection of ether into the engine during
start attempts. Injection of excessive ether may result in an
uncontrolled internal engine explosion that could cause engine
damage. Follow the manufacturer's instructions on proper
product use.
Follow the instructions on the container or by the manufacturer of the starting aid.
36
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Turbocharger Compressor Inlet Shield
A turbocharger compressor inlet shield, J 26554-A, is available and must be used anytime the
engine is operated with the air inlet piping removed. See Figure 14. The shield helps to prevent
foreign objects from entering and damaging the turbocharger and will prevent the mechanic from
accidentally touching the turbocharger impeller. The use of this shield does NOT preclude any
other safety practices contained in this manual. See Figure 15 for Series 60G engine.
To avoid injury from contact with rotating parts when an
engine is operating with the air inlet piping removed, install
an air inlet screen shield over the turbocharger air inlet. The
shield prevents contact with rotating parts.
Use of this shield does NOT preclude any other safety practices contained in this manual.
Figure 14
Turbocharger Compressor Inlet Shield
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Figure 15
38
Turbocharger Compressor Inlet Shield, Series 60G Engine
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
FLUOROELASTOMER (VITON) CAUTION
Under normal design conditions, fluoroelastomer (VITON) parts, such as O-rings and seals,
are perfectly safe to handle.
To avoid injury from chemical burns, wear a face
shield and neoprene or PVC gloves when handling
fluoroelastomer O-rings or seals that have been degraded
by excessive heat. Discard gloves after handling degraded
fluoroelastomer parts.
However, a potential hazard may occur if these components are raised to a temperature above
316 C (600 F), such as during a cylinder failure or engine fire. At temperatures above 316 C
(600 F) fluoroelastomer will decompose (indicated by charring or the appearance of a black,
sticky mass) and produce hydrofluoric acid. This is extremely corrosive and, if touched by bare
skin, may cause severe burns, sometimes with symptoms delayed for several hours.
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
ENGINE VIEWS
The engine views show the pre-1991 engine and 1991 and later engine as well as DDEC II and
DDEC III/IV. See Figure 16. For Series 60G engine views see Figure 17, see Figure 18and
see Figure 19.
Figure 16
40
Engine Views
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Figure 17
Engine Views (60G Genset Engine)
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Figure 18
42
Engine Views (60G Automotive Engine)
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Figure 19
Engine Views (Heat-Exchanger-Cooled Marine Engine)
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Figure 20
44
Engine Views Series 60 2002 Exhaust Gas Recirculation (EGR)
Engine
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
ENGLISH TO METRIC CONVERSION
Listed in Table 5 are the English to metric conversions.
Multiply Length
By
To get equivalent number of:
Inch (in.)
25.4
Millimeters (mm)
Foot (ft)
0.3048
Meters (m)
Yard (yd)
0.9144
Meters (m)
Mile (mile)
1.609
Kilometers (km)
Multiply Area
By
To get equivalent number of:
Inch2 (in.2)
645.2
Millimeters2 (mm2)
Inch2 (in.2)
6.45
Centimeters2 (cm2)
Foot2 (ft2)
0.0929
Meters2 (m2)
Yard2 (yd2)
0.8361
Meters2 (m2)
Multiply Volume
By
To get equivalent number of:
3
3
Inch (in. )
16387
Millimeters3 (mm3)
Inch3 (in.3)
16.387
Centimeters3 (cm3)
Inch3 (in.3)
0.0164
Liters (L)
Quart (qt)
0.9464
Liters (L)
Gallon (gal)
3.785
Liters (L)
Yard3 (yd3)
0.7646
Meters3 (m3)
Multiply Mass
By
To get equivalent number of:
Pound (lb)
0.4536
Kilograms (kg)
Ton (ton)
907.18
Kilograms (kg)
Ton (ton)
0.907
Tonne (t)
Multiply Force
By
To get equivalent number of:
Kilogram (kg)
9.807
Newtons (N)
Ounce (oz)
0.2780
Newtons (N)
Pound (lb)
4.448
Newtons (N)
Multiply Temperature
By
To get equivalent number of:
Degree Fahrenheit ( F)
( F-32) ÷ 1.8
Degree Celsius ( C)
Multiply Acceleration
By
To get equivalent number of:
Foot/second2 (ft/sec2)
0.3048
Meter/second2 (m/s2)
Inch/second2 (in./sec2)
0.0254
Meter/second2 (m/s2)
Multiply Torque
By
To get equivalent number of:
Pound-inch (lb·in.)
0.11298
Newton-meters (N·m)
Pound-foot (lb·ft)
1.3558
Newton-meters (N·m)
Multiply Power
By
To get equivalent number of:
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
Multiply Length
By
To get equivalent number of:
Horsepower (hp)
0.746
Kilowatts (kW)
Multiply Power
By
To get equivalent number of:
Inches of water (in. H2 O)
0.2491
Kilopascals (kPa)
2
Pounds/square in. (lb/in. )
6.895
Kilopascals (kPa)
Multiply Energy or Work
By
To get equivalent number of:
British Thermal Unit (Btu)
1055
Joules (J)
Foot-pound (ft·lb)
1.3558
Joules (J)
kilowatt-hour (kW·hr)
3,600,000. or 3.6 x 106
Joules (J = one W/s)
Multiply Light
By
To get equivalent number of:
Foot candle (fc)
10.764
Lumens/meter2 (lm/m2)
Multiply Fuel Performance
By
To get equivalent number of:
Miles/gal (mile/gal)
0.4251
Kilometers/liter (km/L)
Gallons/mile (gal/mile)
2.3527
Liter/kilometer (L/km)
Multiply Velocity
By
To get equivalent number of:
Miles/hour (mile/hr)
1.6093
Kilometers/hour (km/hr)
Table 5
English to Metric Conversion Table
DECIMAL AND METRIC EQUIVALENTS
Listed in Table 6 are the decimal and metric equivalents:
46
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Fractions of an
inch
Decimal
(in.)
Metric
(mm)
Fractions of an inch
Decimal (in.)
Metric
(mm)
1/64
0.015625
0.39688
33/64
0.515625
13.09687
1/32
0.03125
0.79375
17/32
0.53125
13.49375
3/64
0.046875
1.19062
35/64
0.546875
13.89062
1/16
0.0625
1.58750
9/16
0.5625
14.28750
5/64
0.078125
1.98437
37/64
0.578125
14.68437
3/32
0.09375
2.38125
19/32
0.59375
15.08125
7/64
0.109375
2.77812
39/64
0.609375
15.47812
1/8
0.125
3.175
5/8
0.625
15.87500
9/64
0.140625
3.57187
41/64
0.640625
16.27187
5/32
0.15625
3.96875
21/32
0.65625
16.66875
11/64
0.171875
4.36562
43/64
0.671875
17.06562
3/16
0.1875
4.76250
11/16
0.6875
17.46250
13/64
0.203125
5.15937
45/64
0.703125
17.85937
7/32
0.21875
5.55625
23/32
0.71875
18.25625
15/64
0.234375
5.95312
47/64
0.734375
18.65312
1/4
0.250
6.35000
3/4
0.750
19.05000
17/64
0.265625
6.74687
49/64
0.765625
19.44687
9/32
0.28125
7.14375
25/32
0.78125
19.84375
19/64
0.296875
7.54062
51/64
0.796875
20.24062
5/16
0.3125
7.93750
13/16
0.8125
20.63750
21/64
0.328125
8.33437
53/64
0.828125
21.03437
11/32
0.34375
8.73125
27/32
0.84375
21.43125
23/64
0.359375
9.12812
55/64
0.859375
21.82812
3/8
0.375
9.52500
7/8
0.875
22.22500
25/64
0.390625
9.92187
57/64
0.890625
22.62187
13/32
0.40625
10.31875
29/32
0.90625
23.01875
27/64
0.421875
10.71562
59/64
0.921875
23.41562
7/16
0.4375
11.11250
15/16
0.9375
23.81250
29/64
0.453125
11.50937
61/64
0.953125
24.20937
15/32
0.46875
11.90625
31/32
0.96875
24.60625
31/64
0.484375
12.30312
63/64
0.984375
25.00312
1/2
0.500
12.70000
1
1.00
25.40000
Table 6
Conversion Chart-Customary and Metric Units
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
SPECIFICATIONS
This section contains fastener torque specifications and pipe plug torque specifications.
Torque Specifications - Fasteners
The proper bolt and nut torque is dependent on its size. Standard (non-metric) nut and bolt
torque specifications are listed in Table 7. The proper torque specifications for metric nuts and
bolts are listed in Table 8.
Nut and Bolt Size, mm
280M or Better Torque, N·m
280M or Better Torque, lb·ft
No.10-24
5-7
4-5
1/4 in.-20
9-12
7-9
1/4 in.-28
11-14
8-10
5/16 in.-18
18-23
13-17
5/16 in.-24
20-26
15-19
3/8 in.-16
41-47
30-35
3/8 in.-24
47-53
35-39
7/16 in.-14
62-68
46-50
7/16 in.-20
77-83
57-61
1/2 in.-13
96-102
71-75
1/2 in.-20
112-126
83-93
9/16 in.-12
122-136
90-100
9/16 in.-18
145-159
107-117
5/8 in.-11
186-199
137-147
5/8 in.-18
228-241
168-178
3/4 in.-10
325-339
240-250
3/4 in.-16
393-407
290-300
7/8 in.-9
556-569
410-420
7/8 in.-14
644-657
475-485
1 in.-8
789-799
580-590
1 in.-14
928-942
685-695
Table 7
48
Standard (Non-metric) Fastener Torque Specifications
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Nut and Bolt Size, mm
Property Class 10.9 Torque, N·m
Property Class 10.9 Torque, lb·ft
M6 X 1.0
13-16
10-12
M8 X 1.25
30-38
22-28
M10 X 1.5
58-73
43-54
M12 X 1.75
101-126
75-93
M14 X 2.0
160-200
118-148
M16 X 2.0
245-306
181-226
M20 X 2.5
478-598
353-441
Table 8
Class 10.9 Torque Specifications for Metric Fasteners
Torque Specification - Pipe Plugs
Standard pipe plug torque specifications supporting the Series 60 engine are listed in Table 9.
*Pipe Plug Size, NPTF
Torque Specifications, N·m
Torque Specifications, lb·ft
1/8 in.
14-18
10-13
1/4 in.
19-24
14-18
3/8 in.
24-31
18-23
1/2 in.
31-39
23-29
3/4 in.
45-56
33-41
1 in.
101-126
75-93
1-1/4 in.
129-161
95-119
1-1/2 in.
149-187
110-138
*Use sealant such as Pipe Plug Sealant with Teflon®, PT-7271 (Loctite® 592), or equivalent on all uncoated pipe plugs.
Table 9
Standard Pipe Plug Torque Specifications
All information subject to change without notice.
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
50
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
1
ENGINE
Section
Page
1.1
CYLINDER BLOCK AND CYLINDER LINER ..........................................
1-3
1.2
CYLINDER HEAD ....................................................................................
1-30
1.3
VALVE AND INJECTOR OPERATING MECHANISM ..............................
1-64
1.4
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS .......
1-86
1.5
ENGINE LIFTER BRACKETS .................................................................. 1-118
1.6
ROCKER COVER .................................................................................... 1-126
1.7
CRANKSHAFT ........................................................................................ 1-148
1.8
CRANKSHAFT OIL SEALS ..................................................................... 1-169
1.9
CRANKSHAFT MAIN BEARINGS ........................................................... 1-190
1.10
GEAR CASE COVER .............................................................................. 1-203
1.11
GEAR CASE ............................................................................................ 1-237
1.12
CRANKSHAFT VIBRATION DAMPER ..................................................... 1-269
1.13
CRANKSHAFT PULLEY .......................................................................... 1-278
1.14
FLYWHEEL ............................................................................................. 1-294
1.15
RING GEAR ............................................................................................. 1-304
1.16
FLYWHEEL HOUSING ............................................................................. 1-306
1.17
PISTON AND PISTON RING ................................................................... 1-314
1.18
FORGED STEEL ONE PIECE PISTON ASSEMBLY AND PISTON
RING ........................................................................................................ 1-337
1.19
PISTON AND CONNECTING ROD ASSEMBLY ..................................... 1-352
1.20
CONNECTING ROD ................................................................................ 1-383
1.21
CYLINDER LINER ................................................................................... 1-398
1.22
GEAR TRAIN AND ENGINE TIMING ...................................................... 1-413
1.23
THRUST PLATE PERIMETER SEAL ....................................................... 1-443
1.24
CAMSHAFT AND CAMSHAFT BEARING ............................................... 1-458
1.25
CAMSHAFT DRIVE GEAR ...................................................................... 1-510
1.26
ADJUSTABLE IDLER GEAR ASSEMBLY ................................................ 1-524
1.27
BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY ..................... 1-535
1.28
CRANKSHAFT TIMING GEAR AND TIMING WHEEL ............................ 1-549
1.29
ACCESSORY DRIVE ............................................................................... 1-570
1.30
JAKE BRAKE® ......................................................................................... 1-603
1.A
ADDITIONAL INFORMATION .................................................................. 1-663
1-2
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1
CYLINDER BLOCK AND CYLINDER LINER
The cylinder block is the basic engine structure, establishing and maintaining the alignment of all
engine working parts. In the Series 60 Engine, the cylinder bores are not an integral part of the
block casting, but are in the form of replaceable, wet type cylinder liners. See Figure 1-1.
Flanges at the liner upper ends seat in counterbores in the block deck, and project slightly above
the deck to compress the head gasket for a good compression seal. Below the water jacket the
lower end of the cylinder liner has two D-shaped seal rings and a lipped crevice seal to prevent
leakage between the water jacket and crankcase.
1. Cylinder Block
4. Cylinder Liner
2. D-rings
5. Integral Coolant Inlet Manifold
3. Crevice Seal
6. Oil Galleries
Figure 1-1
Series 60 Cylinder Block and Liner
All information subject to change without notice.
(Rev. 2004)
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1-3
1.1
CYLINDER BLOCK AND CYLINDER LINER
An integral coolant inlet manifold is cored into the right side of the block. It distributes the
water pump output along the length of the block. Oil galleries are machined into the cooler
side of the block. See Figure 1-1.
The integral oil galleries direct the oil pump output through the external oil cooler and filters, to
the main oil gallery and to drilled passages in the crankcase webs which supply oil under pressure
to each main bearing. In the crankcase, five integral webs plus front and rear bulkheads support
the crankshaft in seven main bearings. See Figure 1-2.
Figure 1-2
Series 60 Cylinder Block Crankcase
An improved cylinder block has replaced the former block on all Series 60 engines. This change
took effect with unit serial number 6R210293, built November 30, 1994. The former cylinder
block was used on engines built prior to this serial number.
The Series 60 cylinder block was further improved by the addition of a drilled lubrication orifice
and bolt hole at the base of each cylinder bore. See Figure 1-2. The orifices are drilled into the
main oil gallery and are required for installation of bolt-on oil spray nozzles used with forged
steel pistons on premium engines. When blocks are used for non-premium engines with cast-iron
pistons, the lubrication orifices are closed with bolt-on steel plates. First usage of the drilled block
was on May 2, 1998, effective with engine serial number 6R408505.
1-4
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
The improved block permits installation of adaptorless Bendix and Midland air compressors onto
the gear case. The improved block is similar to the former block, except that it has a slightly
modified sidewall configuration that eliminates interference between the block and the adaptorless
compressor. To compensate for the elimination of the adaptor, air compressor mounting bracket
bolt holes have been moved forward 130.3 mm (5.13 in.) on the block. See Figure 1-3. Since
these holes have a different spacing than the former holes, an improved compressor mounting
bracket is required. A new air compressor coolant supply port has also been added forward of the
former supply port. The former port is plugged when the adaptorless compressor is installed.
Figure 1-3
Cylinder Block Showing Current Modifications
When replacing a former block with an improved block, it is recommended (but not necessary)
that an adaptorless air compressor, improved compressor mounting bracket, and improved
compressor coolant supply hose be installed. Refer to section 10.1.3, of this manual for
information on installing the adaptorless air compressor.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
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1.1
CYLINDER BLOCK AND CYLINDER LINER
1.1.1
Repair or Replacement of Cylinder Block
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-4.
Figure 1-4
1-6
Flowchart for Repair or Replacement of Cylinder Block
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
1.1.2
Removal and Disassembly of Engine from the Vehicle or Vessel
Before mounting an engine on an overhaul stand, it must be disconnected from the transmission.
Details for removing an engine will vary from one application to another. However, the following
steps will be necessary, regardless of application:
1. Disconnect the battery cable(s) from the battery(s).
2. Drain the cooling system completely by removing the drain plug in the oil cooler and
opening the drain cocks in the cylinder block, thermostat housing and water pump
housing. Refer to section 13.13.4.
NOTE:
On marine engines, drain the heat exchanger, charge air cooler and water-cooled intake
manifold, if installed.
3. Drain the lubricating oil. Refer to section 13.13.1.
4. Disconnect the inlet fuel line from the primary fuel filter and the outlet line from the upper
fitting at the rear of the cylinder head. Refer to section 2.10.1.
5. Remove the air cleaner ducting as necessary for engine removal. Refer to OEM guidelines.
6. Remove the charge air cooler ducting from the turbocharger and intake manifold.
Refer to section 6.10.2.
7. Disconnect the exhaust piping from the turbocharger. Refer to section 6.6.2.
8. Disconnect DDEC:
[a]
For DDEC I, disconnect the 22-pin DDEC electrical connector.
Refer to section 2.21.2.
[b]
For DDEC II or III, disconnect the 30-pin DDEC vehicle electrical connector and
the six-pin DDEC II power connector or DDEC III/IV five pin power connector.
Refer to section 2.19.2, or refer to section 2.20.3.
9. Disconnect and remove the cranking motor. Refer to section 8.4.2.
10. Remove the alternator and other electrical equipment, as necessary. Refer to section 8.2.2.
11. Remove the air compressor and any air lines, as necessary. Refer to section 10.1.5.
12. Disconnect and remove the coolant hoses.
13. On marine engines, remove the raw water pump.Refer to section 4.4.2.
14. Remove the charge air cooler, radiator, fan guard and other cooling system related parts as
necessary to remove the engine. Refer to section 6.10.2.
NOTE:
On certain keel cooled marine engines, remove the front-mounted charge air cooler and
mounting, if installed. Refer to section 4.4.2.
All information subject to change without notice.
(Rev. 2004)
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CYLINDER BLOCK AND CYLINDER LINER
15. Connect a suitable lifting device to the engine using all three lifting brackets (two at the
rear and one at the front).
16. Separate the engine from the transmission or marine gear.
17. Remove the engine mounting bolts.
To avoid injury from a falling engine, an adequate lifting
device with a spreader bar and sling should be used to lift
the engine. The sling and spreader bar should be adjusted
so the lifting hooks are vertical to prevent bending the lifter
brackets. To ensure proper weight distribution, all provided
lifter brackets must be used.
18. Lift the engine from its mounts using a suitable lifting device. See Figure 1-5.
Figure 1-5
1-8
Lifting Engine
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
To avoid injury from a falling engine, ensure the engine
is securely attached to the engine overhaul stand before
releasing the lifting sling.
19. Use engine overhaul stand, J 29109, with stand adaptor plate, J 35635-1 part of J 35635–A
for support when stripping a Series 60 engine cylinder block. See Figure 1-6.
Figure 1-6
Engine Overhaul Stand and Adaptor
All information subject to change without notice.
(Rev. 2004)
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1.1
CYLINDER BLOCK AND CYLINDER LINER
20. Bolt cylinder block adaptor, J 35635-2 part of J 35635–A, to the cylinder block and mate it
with the stand adaptor, J 35635-1 part of J 35635–A. See Figure 1-7.
Figure 1-7
Cylinder Block Adaptor
21. The engine is left-side mounted in an upright position. Rotate it in either direction and
lock it into position.
22. Remove the fuel filters and adaptor.
[a]
For DDEC I engines, remove the inlet and outlet fuel lines connected to the
Electronic Distributor Unit (EDU) cold plate, the EDU mounting bolts, and the
EDU. Refer to section 2.21.2.
[b]
For DDEC II engines, remove the inlet and outlet fuel lines connected to the
Electronic Control Module (ECM) cold plate, the ECM mounting bolts, and the
ECM. Refer to section 2.20.3.
NOTE:
DDC has discontinued the use of the ECM cold plate on all Series 60 automotive engine
models, effective with unit serial number 06R0008950. In place of the ECM cold plate, a
No. 6 x 37.92 in. (963 mm) long hose assembly (23504785) is now routed from the fuel
pump discharge fitting to the inlet of the secondary fuel filter.
1-10
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
[c]
Current DDEC III/IV Series 60 vehicle, industrial and generator set engines do
not have a cold plate.
NOTE:
Series 60 marine engines DO have a cold plate.
23. Disconnect the harness connector (gray) from the timing reference sensor (TRS) at the
lower left corner of the gear case. Remove the TRS from the gear case. Refer to section
2.33.2.
24. Disconnect the harness (black) connector from the synchronous reference sensor (SRS) at
the left rear wall of the gear case. Remove the SRS from the gear case. Refer to section
2.32.2.
25. Remove any electrical components, connectors or wiring looms from the engine.
26. With the engine mounted on the overhaul stand, remove all of any remaining
subassemblies and parts from the cylinder block.
[a]
To remove the one piece valve rocker cover, refer to section 1.6.2.
[b]
To remove the two piece valve rocker cover, refer to section 1.6.3.
[c]
To remove the three piece valve rocker cover. Refer to section 1.6.5.
[d]
Remove the engine lifter brackets, refer to section 1.5.2.
[e]
Remove the crankshaft pulley, refer to section 1.13.2.
[f]
Remove the crankshaft vibration damper, refer to section 1.12.2.
[g]
Remove the accessory drive, refer to section 1.29.2.
[h]
Remove the gear case cover, refer to section 1.10.2.
[i]
Remove the camshaft drive gear, refer to section 1.25.2.
[j]
Remove the bull gear and camshaft idler gear assembly, refer to section 1.27.2.
[k]
Remove the adjustable idler gear assembly, refer to section 1.26.2.
[l]
Remove the crankshaft timing gear and timing wheel, refer to section 1.28.2.
[m]
Remove the gear case, refer to section 1.11.2.
[n]
Remove the camshaft, refer to section 1.24.2.
[o]
Remove the cylinder head, refer to section 1.2.2.
[p]
Remove the flywheel, refer to section 1.14.2.
[q]
Remove the flywheel housing, refer to section 1.16.2.
[r]
Remove the oil pan, refer to section 3.11.2.
[s]
Remove the piston and connecting rod assembly, refer to section 1.19.2.
[t]
Remove the crankshaft, refer to section 1.7.2.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
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1.1
CYLINDER BLOCK AND CYLINDER LINER
NOTICE:
Before removing main bearing caps, be sure each is stamped
or punch-marked in numerical order, beginning with No. 1 at
the front, to ensure installation in their original position. Mark all
caps on the oil cooler side (right side) of the engine to prevent
reversal at assembly. Failure to mark numerical order may result
in the caps being put back in incorrect order, improper crankshaft
support and severe crankshaft or bearing damage or both.
[u]
1.1.3
Remove the crankshaft main bearings, refer to section 1.9.2.
Cleaning the Cylinder Block
Before removing cylinder liners for block cleaning, the liner bores should be gaged to determine
whether liner replacement is necessary. Refer to section 1.21.2.2.
Remove cylinder liners with the cylinder liner removal tool, J 35791, before putting the block
in cleaning or descaling baths, to avoid trapping cleaning agents in block liner seating bores.
See Figure 1-8.
Figure 1-8
1-12
Cylinder Liner Removal Tool
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
After disassembling and before removing the cylinder block from the overhaul stand for cleaning
and inspection, install the two metric eye bolts J 35595 to the cylinder block. See Figure 1-9.
Figure 1-9
Cylinder Block Test Deck Plate Installation
Clean the cylinder block as follows:
1. Remove all oil and water gallery and weep hole plugs to allow the cleaning solution to
enter the inside of the oil and water passages. On current block, remove bolt-on plate or
piston-cooling oil spray nozzle at the base of each cylinder bore.
2. Immerse and agitate the block in a hot bath of a commercial, heavy-duty alkaline solution.
3. Wash the block in hot water or steam clean it to remove the alkaline solution.
4. If the water jackets are heavily scaled, proceed as follows:
[a]
Immerse and agitate the block in a bath of inhibited phosphoric acid.
[b]
Allow the block to remain in the acid bath until the bubbling action stops
(approximately 30 minutes).
[c]
Lift the block, drain it and immerse it again in the same acid solution for 10 more
minutes. Repeat until all scale is removed from the water jacket area.
[d]
Rinse the block in clear, hot water to remove the acid solution.
[e]
Neutralize the acid that may cling to the casting by immersing the block in an
alkaline bath.
[f]
Wash the block in clean water or steam clean it.
All information subject to change without notice.
(Rev. 2004)
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CYLINDER BLOCK AND CYLINDER LINER
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
5. Dry the cylinder block with compressed air. Blow out all of the bolt holes and passages
with compressed air.
NOTE:
The above cleaning procedure may be used on all ordinary cast iron and steel parts for
the engine. Aluminum parts, such as flywheel housing, air intake manifold, oil filter
adaptor and the camshaft gear access cover should NOT be cleaned in this manner.
Mention will be made of special procedures when necessary.
6. Be certain that all water passages and oil galleries have been thoroughly cleaned and
dried. Install weep hole plugs and precoated pipe plugs. Install new cup plugs using
a coating of good grade non-hardening sealant such as Loctite® 620 or equivalent.
Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Chart."
7. Pressure test the cylinder block. Two methods of cylinder block pressure testing may be
used depending on the test facilities available:
1-14
[a]
Immersion method; refer to section 1.1.3.1.
[b]
Leak-marker method; refer to section 1.1.3.2.
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
1.1.3.1
Testing the Cylinder Block (Immersion Pressure Method)
Use cylinder block pressure test kit, J 36223–D, for immersion method pressure testing as follows:
1. Install cylinder liners with new seal rings and crevice seals. Refer to section 1.21.3. Seat
the liners firmly in the block counterbores with cylinder liner installation tool, J 35597.
2. Install two metric eye bolts, J 35595, in the head bolt holes at opposite ends of the
block. See Figure 1-10.
Figure 1-10
Cylinder Block Test Deck Plate Installation
3. Install the cylinder block test strips and rings. See Figure 1-10.
4. Install the bolts through the strips and into the cylinder block. Torque the bolts on the
ring strips to 230-237 N·m (170-175 lb·ft). Torque the bolts on the outside strips to 14
N·m (10 lb·ft).
NOTE:
Because of a design change to the 1991 cylinder block, the water inlet cover plate tool
has changed. Refer to section ADDITIONAL INFORMATION1.A, for instructions on
modifying the former tool, J 36223-7, part of J 36223–D.
All information subject to change without notice.
(Rev. 2004)
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1.1
CYLINDER BLOCK AND CYLINDER LINER
5. Install the water inlet cover plate, J 36223-7A, part of J 36223–D. See Figure 1-11. Use
the bolt supplied with the tool to secure it to the cylinder block.
Figure 1-11
Water Inlet Cover Plate Installation
NOTE:
At the base of each liner, the space between upper and lower liner seals is vented to the
block surface on the left side. Any coolant leakage past the upper seal is drained to the
outside rather than into the crankcase, and is easily detected by a visual inspection.
6. With a suitable lifting device and spreadable bars, immerse the cylinder block for twenty
minutes in a tank of water heated to 82-93 C (180-200 F).
7. Attach an air line to the water inlet cover plate and apply 138 kPa (20 lb/in.2) air pressure
to the water jacket. Observe the water in the tank for bubbles that will indicate cracks or
leaks. A cracked cylinder block must be replaced by a new block.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
8. Remove the block from the water tank. Remove the plates and gaskets and blow out all of
the passages in the block with compressed air.
9. Remount the cylinder block to the engine overhaul stand, J 29109. See Figure 1-6.
1-16
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1.3.2
Testing the Cylinder Block (Leak-Marker Pressure)
When a large water tank is not available, or when it is desired to check the block for cracks
without removing the engine from the vehicle cylinder block, leak-marker pressure testing may be
used. However, it is necessary to remove the cylinder head, oil cooler, and oil pan.
1. Install cylinder liners with new seal rings and crevice seals. Refer to section 1.21.3. Seat
the liners firmly in the block counterbores with cylinder liner installation tool, J 35597.
2. Install two metric eye bolts, J 35595, in the head bolt holes at opposite ends of the
block. See Figure 1-10.
3. Fill the water jacket with a mixture of water and 3.8 liters (1 U.S. gallon) of
permanent-type antifreeze. The antifreeze will penetrate small cracks and its color will
aid in detecting their presence.
4. Install the cylinder block test strips and rings. See Figure 1-10.
5. Install the bolts through the strips and into the cylinder block. Torque the bolts on the
ring strips to 230-237 N·m (170-175 lb·ft). Torque the bolts on the outside strips to 14
N·m (10 lb·ft).
6. Install the water inlet cover plate, J 36223-7A part of J 36223–D. See Figure 1-11. Use
the bolt supplied with the tool to secure it to the cylinder block.
NOTE:
At the base of each liner, the space between upper and lower liner seals is vented to the
block surface, on the left side. Any coolant leakage past the upper seal is drained to the
outside rather than into the crankcase, and is easily detected by a visual inspection.
NOTE:
Because of a design change to the 1991 cylinder block, the water inlet cover plate tool
has changed. Refer to section ADDITIONAL INFORMATION1.A, for instructions on
modifying the former tool, J 36223-7 part of J 36223–D.
All information subject to change without notice.
(Rev. 2004)
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1.1
CYLINDER BLOCK AND CYLINDER LINER
7. Apply 138 kPa (20 lb/in.2) air pressure to the water jacket and maintain this pressure for
at least two hours to give the water and antifreeze mixture ample time to work its way
through any cracks which may exist.
8. At the end of this test period, examine the outside diameter area of the liner flanges, oil
passages, crankcase and exterior of the block for presence of the water and antifreeze
mixture, which will indicate the presence of cracks. A cracked cylinder block must be
replaced with a new block.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
9. After the pressure test is completed, remove the test deck plate and gasket and the water
inlet cover plate. Drain the water jacket. Then blow out all of the passages in the cylinder
block with compressed air.
10. Remount the cylinder block to the engine overhaul stand, J 29109. See Figure 1-6.
1-18
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1.3.3
Inspection of the Cylinder Block
Perform the following for cylinder block inspection:
1. Remove the cylinder liners and regage to determine whether liner replacement is
necessary. Refer to section 1.21.2.
2. Measure the bore of each cylinder with cylinder bore gage, J 5347-B, which has a dial
indicator calibrated in 0.0001 in. increments. See Figure 1-12.
Figure 1-12
Gaging Cylinder Bores
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
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1.1
CYLINDER BLOCK AND CYLINDER LINER
3. Measure cylinder block bore, at the positions on axis 90 degrees apart. See Figure 1-13. If
the diameter does not exceed the dimensions listed in Table 1-1, the block may be reused.
NOTE:
The above measurements are average gage readings at each position. Also, the
out-of-round must not exceed 0.0254 mm (0.001 in.).
Figure 1-13
Table 1-1
1-20
Maximum Cylinder Block Bore Diameters by Location (After
Clean-up)
Location
Diameter, mm
Diameter, in.
A
149.050 - 149.120
5.868 - 5.871
B
146.050 - 146.120
5.750 - 5.753
C
146.050 - 146.120
5.750 - 5.753
Acceptable Cylinder Bore Diameters
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1.3.4
Inspection of Deck Flatness
Check the cylinder block deck for flatness with an accurate straightedge and feeler gage.
See Figure 1-14.
Figure 1-14
Checking Block Deck for Flatness
Check front-to-rear flatness next to the cylinder liner flanges on both sides, and side-to-side
flatness between the liner flanges. The deck must be flat within 0.127 mm (0.005 in.) front-to-rear,
and flat within 0.076 mm (0.003 in.) side-to-side. If not, the deck must be resurfaced.
All information subject to change without notice.
(Rev. 2004)
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1.1
CYLINDER BLOCK AND CYLINDER LINER
NOTICE:
The camshaft is mounted in the cylinder head so resurfacing of
the block affects the position of the camshaft in relation to the
adjustable idler gear and gear train.
Record the amount of stock removed from the cylinder block by stamping the amount removed
on the cylinder block pad. See Figure 1-15.
Figure 1-15
1-22
Recording Stock Removal on Cylinder Block Pad
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1.3.5
Inspection of Main Bearing Bores
Perform the following steps for main bearing bore inspection:
1. Install the main bearing caps in their original positions. Lubricate the cap bolt threads and
head contact surfaces with a small quantity of International Compound #2®.
International Compound #2® is a registered trademark of IRMCO.
2. Install the main cap bolts and torque to 470-530 N·m (347-391 lb·ft).
3. Measure the main bearing bores using dial bore gage which has a dial indicator calibrated
in 0.0001 in. increments. Set the cylinder bore gage on zero in master setting fixture.
See Figure 1-16.
Figure 1-16
Gaging Main Bearing Bores
The bore diameter specifications is 133.00-133.025 mm (5.236-5.237 in.). Line boring is also
necessary when a bearing cap must be replaced due to breakage or spun-bearing damage.
Refer to section ADDITIONAL INFORMATION1.A, for line bore specifications which are
listed in Table 1-17.
NOTE:
Dial bore master setting fixture should be used to zero the cylinder bore gage.
All information subject to change without notice.
(Rev. 2004)
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1.1
CYLINDER BLOCK AND CYLINDER LINER
1.1.3.6
General Inspection
Check all machined surfaces for nicks or burrs that could affect the fit of mating parts.
Clean up as necessary by stoning. Also inspect all tapped holes for thread damage and retap
or install helical thread inserts as necessary. Replace any loose or damaged dowel pins.
Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Charts" for
specifications.
1.1.3.7
Rust Prevention
After inspection, if the cylinder block is not to be used immediately, spray the machined surfaces
with engine oil.
NOTICE:
Castings free of grease or oil will rust when exposed to the
atmosphere. Rust on machined surfaces may result in leakage.
If the block is to be stored for an extended period of time, spray or dip it in a polar-type rust
preventive such as "Tectyl® 502-C" from Valvoline Oil Company (or equivalent).
Tectyl® is a registered trademark of Ashland Oil, Inc.
1-24
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.1.4
Reassembly of Cylinder Block
After the cylinder block has been cleaned and inspected, assemble the engine as follows:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
1. Before a reconditioned or new service replacement cylinder block is used, steam clean it
to remove the rust preventive and blow out the oil galleries with compressed air.
2. If a new service replacement block is used, stamp the engine serial number and
model number on the pad provided on the left side of the block, just below the deck.
See Figure 1-17.
Figure 1-17
Location of Engine Serial and Model Numbers
3. Also stamp the position numbers on the main bearing caps and the position of the No. 1
bearing on the cooler side of the oil pan mounting flange of the block.
4. Install the main bearing caps in their original positions; refer to section 1.9.3.
All information subject to change without notice.
(Rev. 2004)
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CYLINDER BLOCK AND CYLINDER LINER
NOTICE:
Always check to make sure cooling nozzles are open and
aligned after piston installation. An obstructed, misaligned,
bent, or damaged nozzle may not provide proper piston cooling.
A loosened nozzle may cause a loss of main gallery oil pressure.
In either case, piston overheating or lack of adequate lubrication
may result in severe engine damage.
5. On current non-premium engines with cast iron pistons, install the bolt-on plate over the
oil gallery orifice at the base of each cylinder bore. On premium engines with closed-end
rods and forged steel pistons, install oil spray nozzles into these openings. See Figure 1-18
for location of nozzle. Torque plate nozzle retaining bolts to 30–38 N·m (22–28 lb·ft).
Figure 1-18
1-26
Oil Spray Nozzle Location
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
6. Install all of the required cup plugs. Use a good grade of non-hardening sealant such
as Loctite® 620 (or equivalent). Apply a thin coat of sealant just inside the chamfer
where the plug is to be installed and install using cup plug installation tool set, J 35653.
See Figure 1-19.
Figure 1-19
Cup Plug Installation Tool Set
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
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1.1
CYLINDER BLOCK AND CYLINDER LINER
7. Install all of the required pipe plugs. Refer to section ADDITIONAL INFORMATION
1.A, "Engine Plug and Dowel Charts".
NOTE:
Whenever a pipe plug is removed from the cylinder block, the threads must be coated
with Loctite®, PT-7260, pipe sealant with Teflon, or equivalent, before reassembly.
Certain plugs available from the parts depot already have a sealer applied to the threads.
Although unnecessary, this pre-coating will not be affected if pipe sealer with Teflon is
also applied.
8. With the engine mounted on the overhaul stand, install all of any remaining subassemblies
and parts on the cylinder block.
1-28
[a]
To install the crankshaft main bearings, refer to section 1.9.3.
[b]
To install the crankshaft, refer to section 1.7.3.
[c]
To install the piston and connecting rod assembly, refer to section 1.19.5.
[d]
To install the oil pan, refer to section 3.11.4.
[e]
To install the flywheel housing, refer to section 1.16.3.
[f]
To install the flywheel, refer to section 1.14.3.
[g]
To install the cylinder head, refer to section 1.2.5.
[h]
To install the camshaft, refer to section 1.24.6.
[i]
To install the gear case, refer to section 1.11.3.
[j]
To install the crankshaft timing gear and timing wheel, refer to section 1.28.3.
[k]
To install the adjustable idler gear assembly, refer to section 1.26.3.
[l]
To install the bull gear and camshaft idler gear assembly, refer to section 1.27.3.
[m]
To install the camshaft drive gear, refer to section 1.25.4.
[n]
To install the gear case cover, refer to section 1.10.3.
[o]
To install the accessory drive, refer to section 1.29.5.
[p]
To install the crankshaft vibration damper, refer to section 1.12.3.
[q]
To install the crankshaft pulley, refer to section 1.13.3.
[r]
To install the engine lifter brackets, refer to section 1.5.3.
[s]
To install the valve rocker cover, refer to section 1.6.8(one piece) and
refer to section 1.6.9(two piece and three piece).
[t]
Install any electrical components, connectors or wiring looms that were removed
during disassembly.
[u]
Install the SRS, refer to section 2.32.3.
[v]
Install the TRS, refer to section 2.33.3.
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
[w]
Install the ECM, refer to section 2.21.3for DDEC I, refer to section 2.20.4for
DDEC II, refer to section 2.19.3for DDEC III/IV, and cold plate if required,
refer to section 2.19.3.
[x]
Install a suitable lifting device to the engine. See Figure 1-5.
To avoid injury from a falling engine, ensure the engine
is securely attached to the engine overhaul stand before
releasing the lifting sling.
[y]
Remove the engine from the overhaul stand. See Figure 1-6.
Transfer the engine to a suitable engine dynamometer test stand. Operate the engine on a
dynamometer following the Run-in procedure; refer to section 11.8.3.2.
Install the engine in the equipment from which it was removed.
All information subject to change without notice.
(Rev. 2004)
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1.2
1.2
CYLINDER HEAD
CYLINDER HEAD
The Series 60 cylinder head combines intake and exhaust valve porting and fuel injector seats
with water jacketing to cool the ports, injectors and combustion chamber area. See Figure 1-20.
Figure 1-20
Cylinder Head Assembly and Mating Components
With the overhead camshaft design, the cylinder head assembly includes:
Cylinder head
Valve and injector operating mechanism
Injector, valve guide and related parts
Camshaft and camshaft bearings
1-30
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
The nested roller follower type rocker arms transmit camshaft motion directly to the valves and
injectors. See Figure 1-21.
1. Roller Follower
4. Exhaust Valve Rocker Arm
2. Injector Rocker Arm
5. Camshaft
3. Intake Valve Rocker Arm
Figure 1-21
Cylinder Head Assembly
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
The nested roller follower type rocker arms transmit cam motion directly to the valves.
See Figure 1-22.
1. Roller Follower
3. Exhaust Valve Rocker Arm
2. Intake Valve Rocker Arm
4. Camshaft
5. Spacer
Figure 1-22
1-32
Cylinder Head Assembly (Series 60G Engine)
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
The porting within the cylinder head is cross-flow, with intake and exhaust ports on opposite
sides for minimum restriction and maximum exposure to coolant flow. Four valves are used per
cylinder, two intake and two exhaust. See Figure 1-23.
Figure 1-23
Intake and Exhaust Valve Porting
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
Replaceable valve guides, valve spring seats, valve stem seals, valve rotators and valve seat
inserts are used on all valves. See Figure 1-24.
1. Valve Guide
5. Valve Stem Oil Seal
2. Valve Spring Seat
6. Valve Spring
3. Valve Seat Insert
7. Valve Rotator
4. Valve
8. Valve Keepers
Figure 1-24
1-34
Valve Guides and Related Parts
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Copper injector tubes extending through the cylinder head water jacket are required for the
fuel injectors. The tubes are directly exposed to the coolant. An O-ring seals the injector tube
upper end in the recess. The lower end of the injector tube must be expanded and flared during
the installation process to contain a tight fit in the firedeck bore. A beveled seat machined in the
tube provides a compression-tight seal when the injector is seated, as well as affording effective
heat transfer facilitating injector cooling. Refer to section 2.4.
Fuel galleries machined into the head supply fuel under fuel pump pressure to all injectors, and
excess fuel is returned to the fuel tank. The fuel gallery outlet (restricted) fitting is installed in the
rear of the cylinder head. See Figure 1-25.
Figure 1-25
Fuel Gallery Inlet and Outlet Fittings
All information subject to change without notice.
(Rev. 2004)
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1.2.1
Repair or Replacement of Cylinder Head
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-26.
Figure 1-26
1-36
Flowchart for Repair or Replacement of Cylinder Head
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.2.2
Removal and Cleaning of Cylinder Head
Because optional and accessory equipment varies with the engine application, this procedure
covers only the basic engine. If the engine is equipped with accessories that affect cylinder head
removal, note the mounting details of each to assure correct installation at reassembly.
Remove the cylinder head as follows:
1. Drain the cooling system. Refer to section 13.13.4.
2. Disconnect the exhaust pipe at the turbocharger. Refer to section 6.6.2.
3. Remove the air cleaner and charge air cooler ducting from turbocharger and intake
manifold. Refer to section 6.2.2and refer to section 6.4.2.
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
4. Disconnect the turbocharger coolant supply (if water-cooled), oil supply and drain lines,
and remove the turbocharger if necessary. See Figure 1-27.
1. Elbow, Oil Drain Tube
10. Connector, Oil Supply Tube
2. Bolt, Mounting Bracket
11. Tube Assembly, Turbo Oil Supply
3. Bolt, Oil Drain Tube Clip
12. Clip, Oil Supply Tube
4. Tube, Turbo Oil Drain
13. Bolt, Oil Supply Tube Clip
5. Bolt, Oil Drain Tube Mounting
14. Connector, Oil Supply Tube (to turbocharger)
6. Gasket, Turbo Oil Drain Tube
15. Gasket, Turbo Exhaust Inlet
7. Nut, Turbo Mounting
16. Clip, Oil Drain Tube
8. Washer, Turbo Mounting
17. Bracket, Oil Drain Tube Clip Mounting
9. Turbocharger Assembly
18. Nut, Oil Drain Tube Clip
Figure 1-27
1-38
Turbocharger Oil Lines
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
5. On pleasure craft marine engines, remove water-cooled charge air cooler from cylinder
head. See Figure 1-28
1. Hose
8. Gasket
2. Elbow
9. CAC Mixer
3. Gasket
10. Housing Lower
4. Sleeve
11. Sensor
5. Seal Ring
12. Seal Ring
6. Bolt
13. Air Temperature Sensor
7. Housing Upper
14. Bracket
15. Bolt
Figure 1-28
Intake Manifold and Related Parts (Series 60 Heat
Exchanger-Cooled Pleasure Craft Marine Engine)
All information subject to change without notice.
(Rev. 2004)
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6. Seal the turbocharger compressor inlet and discharge with covers or masking tape. Plug
the oil supply fitting in the turbocharger housing.
7. Remove and inspect the exhaust manifold if necessary. Refer to section 7.2.2 and
refer to section 7.2.3.1. See Figure 1-29, and see Figure 1-30.
1. Exhaust Manifold
Figure 1-29
1-40
2. Heat Shield
Exhaust Manifold (Series 60G Engine)
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Figure 1-30
Exhaust Manifold (Series 60 Commercial Marine Engine)
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
8. Remove and inspect the intake manifold. Refer to section 6.4.2and refer to section 6.4.3.1.
See Figure 1-31for all diesel except pleasure craft marine. See Figure 1-28 for pleasure
craft marine and see Figure 1-32 for natural gas.
1. Air Inlet
6. Air Temperature Sensor
2. Short Bolt (2)
7. Turbo Boost Pressure Sensor Bolt (2)
3. Intake Manifold Gasket (3)
8. Turbo Boost Pressure Sensor
4. Cylinder Head
9. O-ring
5. Manifold Bolt (7)
10. Intake Manifold
Figure 1-31
1-42
Intake Manifold and Related Parts (All Diesel Except Heat
Exchanger-Cooled Pleasure Craft Marine)
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1. Intake Manifold
5. Pipe Plug
2. Intake Manifold Inlet
6. Bolt
3. Intake Manifold Gasket
7. Air Temperature Sensor
4. Cylinder Head
8. Turbo Boost Pressure Sensor
Figure 1-32
Intake Manifold and Related Parts (Natural Gas)
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
9. Open the drain cock location at the bottom of the thermostat housing to allow the coolant
in the housing to drain.
10. Disconnect radiator or heat exchanger, bypass pipe and hose clamps, and remove the
thermostat housing. Refer to section 4.5.2and see Figure 1-33.
1. Thermostat (2)
6. Bypass Tube
2. Pipe Plug
7. Thermostat Housing
3. Bolts, Thermostat Housing-to-Cylinder Head (4)
8. Drain Cock
4. Hose, Coolant
9. Seals, Thermostat Housing (2)
5. Hose Clamps (2)
10. Cylinder Head
Figure 1-33
1-44
Thermostat Housing Removal
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
11. Remove, disassemble, and inspect the valve rocker cover. Refer to section 1.6.2,
(one-piece), refer to section 1.6.3, (two-piece), refer to section 1.6.5, (three-piece) for
removal. Refer to section 1.6.6 for disassembly, and refer to section 1.6.2.1for inspection.
12. Remove Jake Brakes®, if equipped. Refer to section 1.30.2.
Jake Brake® is a registered trademark of Jacobs Vehicle Systems.
13. Remove rocker arm assemblies. Refer to section 1.3.2.
NOTE:
On heat exchanger-cooled pleasure craft marine engines the heat exchanger
must be removed before the camshaft can be disassembled from the engine.
Refer to section 4.12.2.
14. Remove the camshaft. Refer to section 1.24.2.
NOTE:
Using the camshaft gear pilot tool, J 35906, pull the camshaft gear and thrust plate
forward in the gear case until there is approximately a 6.35 mm (1/4 in.) gap between the
cylinder head and the diamond-shaped camshaft thrust plate seal when removing the
cylinder head. See Figure 1-34.
Figure 1-34
Positioning Camshaft Thrust Plate
15. Inspect the rocker arm assemblies and camshaft lobes. Refer to section 1.3.2.2, and
refer to section 1.24.3.1.
All information subject to change without notice.
(Rev. 2004)
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16. Disconnect the fuel inlet and outlet lines at the rear of the cylinder head. See Figure 1-35.
Figure 1-35
Removing Fuel from Cylinder Head Internal Passages
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
17. Blow low pressure compressed air into the inlet fitting for 20 to 30 seconds or until all of
the fuel is purged from the cylinder head.
18. Disconnect the injector wire harness at each injector. Refer to section 2.3.2.
19. Remove the harness mounting flange from the rear of the cylinder head and carefully
remove the harness from the head by pulling the harness through the hole in the cylinder
head. See Figure 1-25.
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(Rev. 2004)
All information subject to change without notice.
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NOTICE:
To avoid possible damage to the injector spray tips, remove the
injectors before lifting the head from the block. If the injectors are
not removed, handle the head carefully when it is off the block
and support the head fire deck on wooden blocks.
20. Remove the fuel injectors. Refer to section 2.3.2.
NOTE:
Fuel must be removed from the cylinder head fuel galleries prior to removing the injectors.
21. Remove the gear case stabilizer bracket at the right and/or left front corner of the head.
22. Remove the head bolts, refer to section 1.2.2, and install the cylinder head lifter bracket,
J 35641-A, using the bolt hole at the inboard center, No. 3 cam cap and two tapped
Jake Brake® bolt holes. See Figure 1-36.
Figure 1-36
Cylinder Head Lift Bracket Removal
All information subject to change without notice.
(Rev. 2004)
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23. Attach a suitable lifting hook to the eyelet in the lift bracket, and lifter the cylinder head
off the engine. See Figure 1-37.
Figure 1-37
Cylinder Head Removal
24. Drain the engine lubricating oil, refer to section13.13.1, to remove any coolant that may
have drained into the oil pan when the water jacket was opened. Remove any coolant
from the cylinder bores.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
1.2.3
Cleaning of Cylinder Head
Clean the cylinder head as follows:
1. Keep parts segregated according to original position to assure proper reassembly, if parts
are to be reused.
2. Remove all threaded plugs.
3. Steam clean the cylinder head once it has been stripped.
4. If coolant passages are heavily coated with scale, remove the injector tubes and cup plugs,
refer to section 2.4.2. Clean the head in a descaling bath, refer to section 1.2.2.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
5. Clean the camshaft and camshaft bearings, valves, springs, valve rotators and rocker shafts
in fuel oil and blow dry with compressed air.
6. Clean the rocker arm assemblies.
1.2.3.1
Inspection of Cylinder Head
The following steps must be performed before inspecting the cylinder head:
1. Replace the plugs removed for cleaning. If the old plugs are reused, coat the plugs with
Loctite® PT-7260 , pipe sealant with Teflon, or equivalent.
NOTE:
If both front fuel galley plugs have been removed, it will be necessary to replace both
plugs.
2. If injector tubes have been removed, install new injector tubes. Refer to section 2.4.1.
3. Install new cup plugs using a good grade non-hardening sealant such as Loctite® 620
or equivalent.
4. Perform the following tests for cylinder head inspection.
[a]
Pressure test, refer to section 1.2.3.2.
[b]
Firedeck straightness test, refer to section 1.2.3.3.
All information subject to change without notice.
(Rev. 2004)
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1.2.3.2
Pressure Testing of Cylinder Head
Perform the following steps to pressure test the cylinder head:
1. Install the test strips (part of cylinder block pressure test kit, J 36223) to the firedeck on
the cylinder head. See Figure 1-38.
Figure 1-38
Cylinder Head Pressure Test Equipment Installation
2. Insert the cylinder head bolts through the cylinder head and test strips. Attach and torque
the nuts (supplied in J 36223) to 14 N·m (10 lb·ft).
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(Rev. 2004)
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3. Install the thermostat opening cover plate, and gasket to the cylinder head using the bolts
provided with the cover plate. See Figure 1-39.
Figure 1-39
Thermostat Opening Cover Plate Installation
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
4. Install dummy fuel injectors, to the injector bores to assure proper seating of the fuel
injector tubes. See Figure 1-40.
Figure 1-40
Dummy Fuel Injector Installation
5. Install the fuel injector crabs and hold-down bolts. Torque the bolts to 58-66 N·m
(43-49 lb·ft). See Figure 1-40.
6. Attach an air hose to the fitting on the thermostat opening cover plate.
7. Apply 207 kPa (30 lb/in.2) air pressure to the cylinder head and immerse the head in a
water bath heated to 82-93 C (180-200 F).
8. Leave the head in the bath for at least 20 minutes to heat thoroughly, while watching for
bubbles indicating a crack or leak.
1-52
[a]
If an injector tube leaks, replace tube(s). Refer to section 2.4.1for removal and
refer to section 2.4.6for installation of new injector tube.
[b]
If a cracked cylinder head is detected, replace the cylinder head. Refer to section 1.2.5.
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.2.3.3
Inspection and Rework for Firedeck Straightness
The large mass and length of the head casting may contain longitudinal warp after it is unbolted
and removed from the engine block. At the time of factory manufacture, the longitudinal warp is
normalized by using a fixture and clamping the casting during machining. The casting is placed
in a fixture and clamped from its locating surfaces (datums). When unclamped, the head casting
resumes its original shape until it is bolted and tightened to the engine block.
Inspect the bottom (firedeck) of the cylinder head for straightness as follows:
1. Use a heavy, accurate straight-edge and feeler gages to check for transverse and
longitudinal warpage. See Figure 1-41.
Figure 1-41
Checking Firedeck Straightness
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2. Also, check for longitudinal warpage in five places and transverse warpage in 12 places,
indicated as A through L in the next illustration. See Figure 1-42.
Figure 1-42
Cylinder Head Measurement Locations
3. The natural warp contained in the casting must be considered when inspecting firedeck
straightness with the head unbolted and unclamped. Natural warpage is not a cause for
correction. The firedeck (unclamped) must be straight within 0.279 mm (0.011 in.)
front-to-rear and 0.076 mm (0.003 in.) side-to-side. Cylinder head specifications are
listed in Table 1-33.
If the cylinder head flatness is outside of the specifications, Detroit Diesel Corporation
recommends replacing the cylinder head.
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(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.2.3.4
Verification of Countersink Geometry
To verify countersink geometry, perform the following steps.
1. Install new injector tubes. Refer to section 2.4.6.
2. Place valves into proper location and check to be sure that valve heads are recessed from
the firedeck surface by at least 1.4-1.8 mm (0.055 -0.071 in.). Listed in Table 1-33.
See Figure 1-43. If not, reduced-thickness valve seat inserts must be installed.
Refer to section 1.4.6.
Figure 1-43
Valve Head-to-Cylinder Head Measurement
All information subject to change without notice.
(Rev. 2004)
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CYLINDER HEAD
1.2.3.5
Inspection and Reworking of Head Bolt Counterbore
To assure clean and non-brinnelled cylinder head bolt counterbores, use J 38189 to resurface
the head bolt washer area.
The procedure and steps for proper use of the tool are as follows:
NOTICE:
There must be no space between the bottom of the cylinder head
and the table top to properly resurface the counterbores.
1. Place the cylinder head on a solid flat surface (preferably a steel table top) that completely
covers the bottom of head.
NOTICE:
Proper use of the J 38189 is important. Failure to use J 38189
properly may result in an incorrect counterbore depth.
2. Protect the valve springs and injector counterbore to keep any loose metal shavings from
getting into valve springs and counterbore during cutting operation.
3. With cylinder head on a flat surface using the 1/8 in. hex wrench supplied with tool,
loosen the stop collar and cutter to permit sliding on pilot.
4. Starting at the front of the cylinder head, place the pilot of the cutter into a cylinder head
bolt hole until the pilot contacts the flat surface beneath the cylinder head.
5. Allow the cutter to contact the counterbore surface. Lock the stop collar while against the
cutter. The cutter now will resurface the counterbore 0.508 mm (0.020 in.).
6. Remove the tool and place a 0.020 in. feeler gage between the cutter and the locked
stop collar.
7. With feeler gage in place, lock the set screw of the cutter, then remove the feeler gage
and loosen the set screw on the stop collar and slide it down tight against the cutter and
retighten.
Perform the following steps to resurface the counterbore 0.508 (0.020 in.):
1. Using a drill motor with a 1/2 in. chuck and a maximum of 450 r/min and a suitable
cutting oil to prolong the life of the cutter and to lubricate the pilot turning in bolt hole,
2. Apply a moderate pressure on the drill motor, continue cutting operation until pilot
bottoms on flat surface and then do not stop drill motor until after being lifted from cutting
surface. This is to eliminate surface marks.
NOTE:
The J 38189 tool pilot has a shoulder stop that will not allow the cutter to remove material
in excess of the Detroit Diesel Corporation specifications.
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(Rev. 2004)
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SERIES 60 SERVICE MANUAL
3. If some of the bolt holes do not clean up completely, continue resurfacing remaining
holes, repeating the operation in. 0.005 in. increments. This will clean up any holes that
may not have cleaned up completely during the first cut.
4. After all counterbores have been resurfaced, remove any loose cutting chips.
5. Steam clean the complete cylinder head.
6. After steam cleaning, inspect the cylinder head for any remaining chips.
7. Reinstall the cylinder head assembly, using 38 of the new ground head bolt washers.
1.2.4
Assembly of Cylinder Head
Perform the following steps for cylinder head assembly:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
NOTICE:
If the cylinder head is to be replaced, the new head must
be thoroughly cleaned before installation to remove all rust
and preventive compound, especially from the fuel and oil
galleries. This can be done by immersion in a bath of fuel oil
or mineral-spirits-based solvent and scrubbing out all openings
with a soft bristle brush. When clean, blow the head dry with
compressed air.
1. Install new precoated pipe plugs or coat the used plugs with pipe sealant with Teflon,
PT-7260, or equivalent. Refer to section ADDITIONAL INFORMATION1.A, "Engine
Plug and Dowel Charts" for specifications.
2. Install all of the required cup plugs using a good grade of non-hardening sealant, such as
Loctite® 620 or equivalent, on the cup plugs. Use cup plug installation tool set, J 35653.
Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Charts"
for specifications.
3. Ensure that all cup and pipe plugs on the front face of the cylinder head are flush or
below the surface.
4. Install valve guides and seats, valves, valve stem seals, valve springs and rotators.
Refer to section 1.4.8and refer to section 1.4.7.
All information subject to change without notice.
(Rev. 2004)
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1.2.5
Installation of Cylinder Head
Perform the following steps for cylinder head installation:
1. Ensure piston domes and the cylinder head and cylinder block firedeck surfaces are clean
and free of foreign matter. Inspect the head bolt holes in both block and head for the
presence of oil, water, dirt, or damaged threads, clean or retap as necessary.
NOTE:
Series 60 Engines built after September 2002 will use a new cylinder head gasket. This
gasket will be identified with a new part number and date code. This new gasket must
be used with the new cylinder head bolts.
2. Position the head gasket on the block and install cylinder head guide studs, J 35784, at
front and rear of the block. See Figure 1-44.
Figure 1-44
1-58
Cylinder Head Guide Studs
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
3. Lift the head into position with lift bracket, J 35641. See Figure 1-45. Lower it into place
over the guide studs, J 35784, until it seats on the block deck dowels. See Figure 1-44.
Figure 1-45
Cylinder Head Installation
4. Remove the guide studs.
5. Install the head bolts with special hardened washers, lubricating the threads and bolt-head
contact areas with a small amount of International Compound #2®, or equivalent.
NOTICE:
Cylinder head mounting bolts are considered single-use
items and must not be reused.
Failure to install new bolts when replacing a cylinder head may
result in improper bolt clamp load, which could cause gasket
failure and severe engine damage.
6. Torque the head bolts to 250-285 N·m (185-210 lb·ft) in the following
sequence. See Figure 1-46. After September 2002 a new cylinder head bolt will be used
for all Series 60 Off-Highway and On-Highway engines. The new bolt will be identified
with white paint and groove on top of bolt. See Figure 1-47. Torque the new head bolts to
298 N·m (220 lb·ft). There is no change to the procedure other than the new torque value.
The new head bolt can be used with the former cylinder head gaskets, the former head
bolts cannot be used with the new head gasket. Former and new bolts must not be mixed.
All information subject to change without notice.
(Rev. 2004)
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Figure 1-46
Cylinder Head Bolt Tightening Sequence
Figure 1-47
Bolt Identification For Series 60 Engines Built After September
2002
1-60
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
NOTICE:
Failure to repeat the cylinder head bolt torque tightening
sequence can result in some head bolts losing their torque
when others are tightened resulting in insufficient clamp load.
7. Repeat the torque sequence to verify all of the head bolts are torqued to specification.
NOTICE:
The hemispherical portion of the injector hold-down crab
washers must be installed facing the crab (pointing down) in
order to prevent damage to the washers. See Figure 1-48.
8. Visually inspect each injector hole tube to ensure they are clean. Install the fuel injectors.
Refer to section 2.3.5. Be sure the injector hold-down crabs are clear of the valve and
injector springs.
Figure 1-48
Injector Hold-Down Crab Washer Installation
9. Install the clamp bolts with hemispherical washers, torque to 58-66 N·m
(43-49 lb·ft).
10. Install the camshaft. Refer to section 1.24.6.
NOTE:
If a cylinder head other than the one removed from the engine, or if a resurfaced cylinder
head is being installed, the three nuts retaining the adjustable idler gear must be
loosened before installing and torquing the camshaft drive gear retaining bolt.
All information subject to change without notice.
(Rev. 2004)
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NOTICE:
The camshaft drive gear-to-adjustable idler gear lash must be
measured/adjusted before the rocker arm shaft assemblies are
installed.
11. Measure and adjust the camshaft drive gear-to-adjustable idler gear lash. Refer to section
1.22.2.1
12. Install the rocker arm shaft assemblies. Refer to section 1.3.3.
13. Install Jacob's Brake assemblies (if equipped). Refer to section 1.30.5.
14. Feed the injector harness wires through the opening at the rear of the cylinder head.
Secure the harness mounting flange to the cylinder head by torque the bolts to
10-15 N·m (7-11 lb·ft).
15. Connect the injector harness wires to their respective injectors. Refer to section 2.3.5.
NOTICE:
Bolts attaching brackets to the gear case are torqued first then
torque the bolt(s) to the cylinder head next.
16. Install the gear case stabilizer bracket at the right and/or left front corner of the
head. Refer to section 1.11.3.
17. Install the thermostats and seals to the thermostat housing. Refer to section 4.5.5.
18. Clean the coolant outlet surfaces of the head and thermostat housing.
19. With the thermostats seated in the housing counterbores, install the housing to the cylinder
head, torque the housing bolts to 58-73 N·m (43-54 lb·ft). Connect the radiator or heat
exchanger and bypass hose couplings and vent line.
20. Remove all traces of the old gasket from the cylinder head and exhaust manifold joint
surfaces. Install the exhaust manifold with new gaskets. Refer to section 7.2.4.
21. Clean the exhaust manifold and turbocharger joint surfaces and install the turbocharger
with a new gasket. Refer to section 6.6.7. If turbocharger is water cooled, connect coolant
supply and return lines.
22. Fill and vent the cooling system. Refer to section 13.13.4. Fill the engine lubrication
system. Refer to section 13.13.1.
23. Connect the exhaust and air-to-air cooler air ducting and install the air cleaner or air
separator.
24. Install any other components that were removed and fill with the required fluids, as
recommended. Refer to OEM guidelines.
1-62
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
25. Start the engine and check for fuel, coolant or oil leaks. Keep the engine running while
you check.
26. Shut down the engine.
All information subject to change without notice.
(Rev. 2004)
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1.3
1.3
VALVE AND INJECTOR OPERATING MECHANISM
VALVE AND INJECTOR OPERATING MECHANISM
The valve and injector operating mechanism is located entirely in the cylinder head.
The Series 60 overhead camshaft design eliminates the need for push rods. Separate camshaft
followers are not needed, since the rocker arms incorporate follower rollers riding directly on the
camshaft lobes, transmitting camshaft motion to the valves and injectors. See Figure 1-49.
Figure 1-49
1-64
Camshaft and Related Parts
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Each of the three rocker arm assemblies contain bushings where the rocker arms are supported
on the rocker arm shafts. These bushings are not serviced separately. Each intake rocker arm
assembly operates two intake valves in each cylinder. Each exhaust rocker arm assembly operates
two exhaust valves in each cylinder. In each set of rocker arm assemblies, the exhaust rocker
assembly is the widest, straddling the intake and fuel injector rocker arm assembly. The center
rocker operates the fuel injector follower. See Figure 1-50.
Figure 1-50
Rocker Arm Identification
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
The fuel injector rocker arm assembly is located between the intake and exhaust rocker arm
assemblies and has a single bushing (not serviced separately). A rocker arm shaft carries three
sets of rocker arm assemblies and is mounted in seats machined into the camshaft bearing caps.
See Figure 1-51and see Figure 1-52.
1. Unitized Valve Adjusting Screw
Assembly; Intake position
5. Rocker Arm Shaft
2. Locknut
6. Unitized Valve Adjusting Screw
Assembly; Exhaust position
3. Intake Rocker Arm Assembly
7. Exhaust Rocker Arm Assembly
4. Fuel Injector Rocker Arm Assembly
8. Unitized Valve Adjusting Screw
Assembly; Injector position
Figure 1-51
1-66
Rocker Arm and Related Parts
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1. Unitized Valve Adjusting Screw
Assembly; Intake position
5. Rocker Arm Shaft
2. Locknut
6. Unitized Valve Adjusting Screw
Assembly; Exhaust position
3. Intake Rocker Arm Assembly
7. Exhaust Rocker Arm Assembly
4. Spacer
Figure 1-52
Rocker Arm and Related Parts (Series 60G Engine)
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
A new injector rocker arm assembly replaced the former injector rocker arm assembly on
all model 6067-GK60 engines beginning with serial number 06R0133091, and on all model
6067-GU60 and 6067-WU60 engines beginning with serial number 06R0157655.
NOTE:
When the current rocker is installed on a phosphated shaft, the shaft should be turned
180 to present a fresh phosphated area to the loaded region of the bushing.
The current assembly has a honed rocker arm shaft bushing, a ceramic cam follower and a new
phosphated (black in color) rocker arm shaft which provides improved wear characteristics. The
phosphated surface is required for the proper break-in of the steel rocker arm shaft bushings.
Current Series 60 engines have rocker arm shafts without flats at the mounting bolt locations. For
these engines, a spacer is installed between the rocker arm shaft and the mounting bolts or nuts
rather than a washer. This allows the rocker arm shaft to be rotated when installing new rocker
arms. When reusing rocker arm assemblies, the rocker arm shaft should not be rotated so that the
same surfaces of the rocker arm assemblies and rocker shafts are in contact with each other.
Vertical oil passages at the front and rear of the cylinder head deliver oil from the cylinder block
front and rear oil galleries to the No. 1 and 7 lower camshaft bearing saddles. From there, the
oil is directed upward (through the enlarged stud hole) to the No. 1 and 7 upper bearing caps.
A drilled passage in each of these caps exits at the rocker arm shaft seat area, where it indexes
with a hole in each rocker arm shaft.
The rocker arm shafts have internal oil passages that deliver oil to the rocker arm bushings and
intermediate upper camshaft bearings. Some of the oil supplied to the rocker arm bushings passes
through the oil hole in the bushing to the rocker arm assemblies. The rocker arm assemblies
contain drilled passages that supply oil to the camshaft roller follower, the roller pin and the
bushing. The rocker arm assemblies also contain drilled passages that supply oil to the unitized
valve adjusting screw assembly and exhaust valve stems and the fuel injector follower.
NOTE:
In December 2000, a new unitized adjusting valve screw assembly now replaces the
former valve adjusting screw, valve button and retainer clip.
The No. 4 camshaft cap is "Y" drilled, forming an oil path connection between the front and rear
rocker arm shafts, to ensure complete lubrication. The oil passage within one rocker arm cylinder
set is shown. See Figure 1-53and see Figure 1-54.
1-68
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1. Exhaust Rocker Arm Assembly
4. Rocker Arm Shaft
2. Fuel Injector Rocker Arm Assembly
5. Cylinder Head
3. Camshaft Cap
6. Intake Rocker Arm Assembly
Figure 1-53
Rocker Arm Assembly Lubrication Schematic with Former Valve
Adjusting Screw Assembly
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
1. Exhaust Rocker Arm Assembly
4. Rocker Arm Shaft
2. Fuel Injector Rocker Arm Assembly
5. Cylinder Head
3. Camshaft Cap
6. Intake Rocker Arm Assembly
Figure 1-54
1-70
Rocker Arm Assembly Lubrication Schematic with Unitized Valve
Adjusting Screw Assemblies
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
1.3.1
Repair or Replacement of Valve and Injector Operating
Mechanism
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-55.
All information subject to change without notice.
(Rev. 2004)
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VALVE AND INJECTOR OPERATING MECHANISM
Figure 1-55
1-72
Flowchart for Repair or Replacement of Valve and Injector
Operating Mechanism and Camshaft
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
1.3.2
Removal of Rocker Arm Assembly
Perform the following steps for rocker arm assembly removal:
NOTE:
If unit is equipped with Jake Brake®, remove brake. Refer to section 1.30.2.
NOTE:
Jake Brakes are not used on the Series 60G engine.
1. If necessary, steam clean the engine around the valve rocker cover and cylinder head
mating area.
NOTE:
High pressure water or steam cleaning should be avoided in the valve rocker
cover/cylinder head area of the Series 60 gas. The ignition system can be affected.
2. Remove the valve rocker cover. Refer to section 1.6.2(one-piece), refer to section 1.6.3(two
piece), and refer to section 1.6.5(three-piece).
3. Remove the rocker arm shaft bolts (No. 2, 3, 4 or 5, 6, 7) and nuts (No. 1 or 8) that
retain the rocker arm shaft assembly to the cylinder head. See Figure 1-56 for Series 60
diesel engine and see Figure 1-57for Series 60 gas engine. For camshaft or cylinder head
removal, both rocker arm shaft assemblies must be removed.
NOTE:
Whenever nuts No. 1 or 8 are loosened or removed, the torque on the corresponding
rocker shaft stud must be checked. Torque to 126–146 N·m (93–108 lb·ft).
All information subject to change without notice.
(Rev. 2004)
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VALVE AND INJECTOR OPERATING MECHANISM
Figure 1-56
Rocker Arm Shaft Bolts and Nut Identification Numbers
Figure 1-57
Rocker Arm Shaft Bolts and Nut Identification Numbers (Series
60G Engine)
1-74
(Rev. 2004)
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
4. Use rocker arm and shaft assembly removal tool, J 35996-A, to remove the rocker arm
shafts, with rocker arm assemblies in place. See Figure 1-58.
NOTE:
Some engines may be equipped with ceramic injector rollers. Use extra caution while
removing and handling.
Figure 1-58
Rocker Arm Shaft Assembly Removal
5. Remove unitized valve adjusting screw assemblies. Then proceed to step 7.
NOTE:
If the unitized valve button separates from the screw, the button and screw must be
replaced with a new Unitized Valve Adjusting Screw assembly. Do not attempt to
reassemble them for reuse in engine. Unitized Valve Adjusting Screws will not be
serviced separately.
NOTE:
If removing a former valve adjusting screw with valve button and retainer clip, proceed
to step 6.
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
6. To remove the valve button or valve button retaining clip, the valve adjusting screw must
be removed from the rocker arm as follows:
NOTICE:
To avoid possible component damage, the valve button retainer
MUST NOT be expanded more than 15.5 mm (0.610 in.). An
adjusting screw is provided on the expander tool to limit the
amount of travel.
[a]
Spread the retaining clip with expander and remove the button. See Figure 1-59.
Figure 1-59
1-76
Valve Button Retainer Clip Removal
[b]
Slide the retaining clip, open end first, down the adjusting screw. It is necessary
to spread the clip slightly so that the open end can pass over the ball head of the
adjusting screw.
[c]
Insert the tips of the expander, J 36347, between the legs of the retaining clip and
expand the clip.
[d]
Insert the groove on the valve button into the legs of the retaining clip.
[e]
Remove the expander and hold the legs of the retainer with the thumb and index
finger.
[f]
Press the valve button towards the screw to seat both legs of the retainer completely
in the groove.
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
7. If further disassembly is necessary, slide the rockers off the shafts, marking or segregating
the parts so that they may be reinstalled in the same position from which they were
removed.
NOTE:
Front and rear rocker arm shaft sections look identical, but must not be reversed, and
must be installed as removed, due to bolt hole center line distances. The DDC logo is
stamped on the outboard end of each rocker shaft to ensure correct assembly and
installation. See Figure 1-60.
Figure 1-60
Rocker Arm Shaft Identification Mark
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
1.3.2.1
Cleaning of Rocker Arm Assemblies
Clean the rocker arm assemblies as follows:
1. Remove the cup plug at one end of the rocker arm shafts to facilitate the removal of any
foreign material lodged behind the plug.
NOTICE:
Do not soak the rocker arms in solvent because this will remove
the lubricant from the cam follower roller bushings.
2. Clean the exterior of the rocker arms only.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
3. Blow dry with compressed air.
4. Soak the rocker shaft in clean fuel oil.
5. Run a wire brush through the oil passage to remove any foreign material or sludge.
6. Clean the exterior of the shaft and blow out the passages and oil holes; and dry with
compressed air.
1-78
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.3.2.2
Inspection of Rocker Arm Assemblies and Camshaft Lobes
Prior to inspection:
1. Install new cup plugs with tool, J 36326, until they are 1.0-1.3 mm (0.040-0.050 in.)
below the surface of the shaft. See Figure 1-61.
Figure 1-61
Rocker Arm Shaft Identification Mark
2. Remove all of the old gasket sealer from the joint face of the No. 1 and 7 camshaft
bearing caps and the cylinder head. Refer to"Gasket Eliminator Removal" in the "General
Information" section.
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
Inspect the rocker arm assemblies and camshaft lobes as follows:
1. Inspect the rocker arm shaft bushing surfaces and rocker arm bushing bores.
[a]
Check the rocker arm shaft bushing surfaces and rocker arm bushing bores for wear
or scoring. If damage was found, replace component.
[b]
If no damage was found, reuse component.
2. Inspect the cam follower rollers.
[a]
Check the cam follower rollers for scoring, pitting, or flat spots. If damage was
found, replace the component.
[b]
If no damage was found, reuse component.
3. Check the cam follower rollers to ensure they turn freely on the roller pins.
[a]
Clearance between the rollers and pins should not be more than 0.08 mm (0.003 in.).
[b]
Replace as necessary.
4. Inspect the camshaft lobes and journals.
[a]
Check the camshaft lobes and journals for scoring, pitting, or flat spots. If damage
was found, replace the component.
[b]
If there is doubt as to the acceptability of the camshaft for further service, determine
the extent of camshaft lobe wear. Refer to section 1.24.3.1.
5. Inspect the valve adjusting screw assemblies.
[a]
If former style valve adjusting screw assembly is damaged; replace with new unitized
valve adjusting screw assembly.
NOTE:
Replace with unitized valve adjusting screw assembly of the correct position.
[b]
If any damage is found on the unitized valve adjusting screw assembly; replace with
new unitized screw assembly.
[c]
If no damage is found on the former style valve adjusting screw or on the new
unitized valve adjusting screw assembly; reuse the components.
NOTE:
Former style valve adjusting screw assemblies and the unitized valve adjusting screw
assemblies are interchangeable and can be mixed in the same engine.
1-80
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1.3.3
Installation of Rocker Arm Shaft Assembly
Perform the following for rocker arm shaft assembly installation:
1. Ensure the cup plugs are properly installed to each end of the rocker arm shafts before the
shafts are installed to the engine. See Figure 1-62. Refer to section 1.3.2.2, step 1.
1. Unitized Valve Adjusting Screw
Assembly; Intake position
5. Rocker Arm Shaft
2. Locknut
6. Unitized Valve Adjusting Screw
Assembly; Exhaust position
3. Intake Rocker Arm Assembly
7. Exhaust Rocker Arm Assembly
4. Fuel Injector Rocker Arm Assembly
8. Unitized Valve Adjusting Screw
Assembly; Injector position
Figure 1-62
Rocker Arm and Related Parts
All information subject to change without notice.
(Rev. 2004)
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1.3
VALVE AND INJECTOR OPERATING MECHANISM
2. Check the torque on the rocker shaft studs to ensure they were not loosened when the nuts
were removed. Torque the studs to 101-116 N·m (75-86 lb·ft).
3. Install the unitized valve adjusting screw assemblies to the rocker arm assemblies.
See Figure 1-62.
NOTE:
There are three different unitized valve adjusting screw assemblies. Ensure the correct
unitized valve adjusting screw assembly is used in the correct location. See Figure 1-63.
NOTE:
Former style valve adjusting screw assemblies can be mixed with new unitized valve
adjusting screw assemblies.
Figure 1-63
Unitized Valve Adjusting Screw Assemblies (Exhaust, Injector
and Intake)
4. Install the rocker arm assemblies to the rocker arm shafts in their original positions. Use
the rocker arm identification marks to ensure correct component assembly. If the rocker
arm shaft does not have flats, decide on the position of the worn surfaces and rotate the
rocker shaft accordingly.
1-82
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
5. Using care to locate the valve button of the unitized valve adjusting screw assemblies to
their respective valve stems and injector followers, install the rocker arm shaft assemblies
to the cylinder head. See Figure 1-64.
Figure 1-64
Rocker Arm Shaft Assembly Installation
6. If the rocker arm shafts do not have flats in the bolt hole locations, rocker shaft spacers
are required.
[a]
If the rocker shafts do not have flats in the bolt hole locations, install the rocker
shaft spacers on the cap bolts and studs.
[b]
If the rocker shafts do have flats in the bolt hole locations, rocker shaft spacers
are not required.
7. Install the inboard camshaft cap bolts for each rocker arm assembly, through the rocker
arm shaft and camshaft cap and into the cylinder head.
8. Install the nuts to the No. 7 and 8 cap studs.
NOTE:
If new rocker arm components are installed, engine oil should be poured over the rocker
arms, rocker shaft, and camshaft as a pre-lubricant.
All information subject to change without notice.
(Rev. 2004)
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VALVE AND INJECTOR OPERATING MECHANISM
9. Torque the rocker arm shaft nuts to 101-116 N·m (75-86 lb·ft) using the sequence.
See Figure 1-65.
Figure 1-65
Rocker Arm Shaft Retaining Bolt and Nut Tightening Sequence
10. Adjust the intake and exhaust valve clearances and set the injector heights. Refer to section
12.2.
11. Install the valve rocker cover. Refer to section 1.6.8(one-piece), refer to section 1.6.9(twopiece) and (three-piece).
12. Install any other components that were removed for this procedure.
1-84
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
13. Start the engine and check for leaks.
14. Shut down the engine when completed.
All information subject to change without notice.
(Rev. 2004)
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1-85
1.4
1.4
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
Four valves per cylinder, two each intake and exhaust, give the Series 60 engine excellent
breathing and cooling characteristics. See Figure 1-66.
Figure 1-66
Intake and Exhaust Valve Arrangements
Valves are made of heat-treated alloys, with heads and stems precision ground. Stem ends are
hardened to minimize wear in contact with the valve rocker buttons.
Hard-alloy valve seat inserts, pressed into both intake and exhaust ports, can be replaced when
worn to restore new engine performance.
1-86
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Valves are positioned and aligned by replaceable valve guides pressed into the cylinder head.
See Figure 1-67.
1. Valve Guide
5. Valve Stem Oil Seal
2. Valve Spring Seat
6. Valve Spring
3. Valve Insert
7. Valve Rotator
4. Valve
8. Valve Keepers
Figure 1-67
Valve Guide and Related Parts
Replacement guides are reamed to close tolerances, and do not require reaming after installation.
All valves are retained by valve rotator spring caps and two-piece tapered valve locks.
All information subject to change without notice.
(Rev. 2004)
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1.4
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
Valve stem oil seals, installed on both intake and exhaust valves, provide controlled valve stem
lubrication while limiting oil consumption.
NOTE:
New valve seat inserts are pre-ground and only need to be checked for concentricity after
installation. Do not grind a new seat insert unless concentricity exceeds 0.05 mm (0.002
in.). Before grinding, be sure the valve guide is not excessively worn or bent, which could
cause an erroneous concentricity reading. If the firedeck has been resurfaced, the valves
will have to be seated deeper to restore the valve head recess depth to specification
limits. Do not grind seat inserts for this purpose. Reduced thickness inserts are available
that are 0.2540, 0.5080 and 0.7620 mm (0.010, 0.020 and 0.030 in.) shallower than
standard. When a reduced thickness valve seat insert is used, a correspondingly thicker
valve spring seat must be used. See Figure 1-68, and see Figure 1-69.
Figure 1-68
1-88
Standard Valve Seat Insert Thickness
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
When servicing exhaust valves, determine which type of exhaust valve is contained in the engine.
If an exhaust valve must be replaced, use the same type that was removed. Do not mix exhaust
valve types within an engine. Both exhaust valves are available from service stock for this
purpose. Exhaust valve lash settings are affected by the type of exhaust valve that is contained
in the engine. The valve lash settings and injector timing height are listed on the valve rocker
cover. Refer to section 12.2.
Figure 1-69
Minimum Valve Stem Diameter
Two types of exhaust valves are used on Series 60 engines. Pre-1991 model engines use a
nickel-based alloy which can be identified by a forged "U" on the combustion face. 1991 model
and beyond engines use an austenitic based alloy which can be identified by a forged "H"
on the combustion face, and by a machined identification ring above the valve lock groove.
See Figure 1-70. The identification ring can be seen from the right side of the engine with rocker
cover removed.
All information subject to change without notice.
(Rev. 2004)
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1.4
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
Series 60G exhaust valves for automotive engines are an inconnel based material. They are
marked with a "J" on the face of the valve and a "J6-E-5" and a green dot on the top of the
stem of the valve.
Figure 1-70
1-90
Exhaust Valve Identification
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
Beginning with engine model number 6R572448, distinguishing an intake valve from an exhaust
valve can be identified by the different size dimples located under the head of the valve, rather
then forged lettering. See Figure 1-70and see Figure 1-71. This applies to all Series 60 diesel
applications with the exception of the marine engine.
Figure 1-71
1.4.1
Location of Dimples on Intake Valves
Repair or Replacement of Valves
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-72.
All information subject to change without notice.
(Rev. 2004)
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1.4
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
Figure 1-72
1.4.2
Flowchart for Repair or Replacement of Valves
Removal and Cleaning of Valve Spring (Cylinder Head Installed)
Perform the following steps for valve spring removal:
1-92
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1. Clean any dirt and debris from the valve rocker cover joint area around the top of the
cylinder head. Remove the valve rocker cover. Refer to section 1.6.2(one-piece),
refer to section 1.6.3(two-piece), refer to section 1.6.5(three-piece).
2. If the engine has a Jake Brake®, remove the Jake Brake® housings that cover the rocker
arm and shaft assembly for the valve to be serviced refer to section 1.30.2.
3. Remove the rocker arm shaft assembly, refer to section 1.3.2.
4. Remove the injector from the appropriate cylinder. Refer to section 2.3.2.
NOTE:
Fuel must be removed from the cylinder head fuel galleries prior to removing the
injectors. Refer to section 2.3.2.
5. Bar the engine over until the cylinder is at top-dead-center (TDC).
6. Insert the threaded portion of the valve spring compressor, J 35580into the threaded
inboard camshaft cap hole adjacent to the valve being worked on. See Figure 1-73.
Figure 1-73
Installing Valve Spring Compressor
7. Position the spring compressor cage portion of the valve spring compressor directly over
the valve spring to be compressed. Engage the dowel of the cage in the closest slot of the
valve spring compressor handle.
All information subject to change without notice.
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NOTICE:
Do not contact the valve with the compressor tool.
8. Compress the valve spring and remove the valve locks using a small magnet to prevent the
locks from falling into the cylinder head oil return galleries.
9. Release the spring and remove the valve rotator and valve spring. If the valve stem oil seal
is to be replaced, remove the seal and discard it.
10. On the other three valves it may be necessary to repeat these steps for cylinders being
worked on. Refer to step 1and the following steps. Last, refer to step 9.
NOTE:
All valve spring or seal removal and replacement must be completed for each cylinder
being serviced while the piston is at top-dead-center, before turning the crankshaft to
work on another cylinder.
1.4.3
Removal and Cleaning of the Valve Spring (Cylinder Head
Removed)
With the cylinder head assembly removed from the engine, remove the valve springs as follows:
1. Bolt the engine overhaul stand adaptor, J 35635-A, to the engine overhaul stand, J 29109,
using the hardware provided with the adaptor. See Figure 1-74.
Figure 1-74
1-94
Engine Overhaul Stand
(Rev. 2004)
All information subject to change without notice.
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2. Bolt the cylinder head adaptor plate, J 35636-A, to the cylinder head using the bolts
provided with the adaptor. See Figure 1-74.
3. Mount the cylinder head and adaptor plate to the overhaul stand adaptor by engaging the
slots in the cylinder head adaptor plate to the dowels on the overhaul stand adaptor.
4. Install the six nut and bolt assemblies that secure the cylinder head adaptor plate to the
overhaul stand adaptor.
5. Remove the cylinder head lifting hardware.
6. Turn the crank of the engine overhaul stand to position the cylinder head in an upright
position.
7. Remove the valve locks using valve spring compressor, J 8062, with jaws, J 8062–3
installed, to compress each valve spring. See Figure 1-75.
Figure 1-75
Compressing Valve Spring
8. Release the spring and remove the valve, valve rotator and valve spring.
9. Remove the valve stem oil seal and discard the seal.
10. Remove the valve spring seat.
11. As parts are removed, mark or segregate them according to their original position for
possible reuse.
All information subject to change without notice.
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1.4.3.1
Cleaning of Valves and Related Parts
Clean the valves and parts as follows:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
1. Using proper eye protection, clean all of the disassembled parts with fuel oil and dry
with compressed air.
2. Clean the carbon from the valve stems and wash the valves with fuel oil.
3. Clean the valve guide bore to remove all gum and carbon deposits.
[a]
For diesel engines; use bore brush, J 5437 (or equivalent) for this procedure.
[b]
For natural gas engines; a cloth or soft nylon brush is recommended for this
procedure.
NOTE:
Do not use bore brush (wire) on natural gas powdered metal guides.
1-96
(Rev. 2004)
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1.4.4
Removal of Valve Guide
Perform the following steps for valve guide removal:
NOTE:
Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasure
craft marine engines.
1. Assemble the valve guide remover, J 34696-B, to an air chisel. See Figure 1-76.
Figure 1-76
Valve Guide Removal Tools
2. Position the cylinder head, firedeck side up, on a turn over stand or supported on 102 x
102 mm (4 x 4 in.) wooden blocks on a workbench.
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3. Insert the tool into valve guide from the firedeck side of the cylinder head. See Figure 1-77.
Figure 1-77
Valve Guide Removal
4. Hold the tool vertical to the cylinder head and drive the valve guide until it is free of
the cylinder head.
5. Clean the valve guide bore with bore brush, J 5437 (or equivalent), to remove all gum
and carbon deposits.
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(Rev. 2004)
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1.4.5
Removal of Intake and Exhaust Valve Seat Insert
As the intake and exhaust valve seats are different in size, two different tools are required for
removal. Use the cam-operated valve seat remover, J 23479-460A, with collet, J 23479-100–A,
to remove the larger intake valve seat insert. Use valve seat remover, J 23479-271, with collet
J 23479-29 to remove the smaller exhaust valve seat insert. See Figure 1-78.
1. Collet
4. Valve Seat Insert Puller
2. Knurled Knob
5. Collar
3. Spring
6. Collet Lever
Figure 1-78
Valve Seat Insert Removal Tools
Remove the intake and exhaust valve seats as follows:
1. Place the cylinder head in a horizontal position with the valve seats facing up.
NOTICE:
Follow instructions supplied with tools J 23479-460A,
J 23479-100, J 23479-271, and J 23479-29 to ensure longer
tool life and unnecessary collet damage.
2. Using a new valve seat insert as a guide, turn the knurled knob on the end of the shaft to
tighten and expand the collet until the valve seat insert will just slip off the collet. Refer to
instructions supplied with the valve seat remover tool for correct tool operation.
All information subject to change without notice.
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1.4.5.1
Inspection of Valve
The valve stems must be free from scratches or scuff marks, and, the valve faces must be free
from ridges or cracks. Some pitting of the valve face is normal, and is acceptable as long as no
leak paths are evident. If leak paths exist, reface the valves or install new valves. If the valve
heads are warped or the valve stem is bent, replace the valves.
If suitable for reuse, a valve may be refaced as long as the valve rim width, after refacing,
is not less than 2.0 mm (0.078 in.) for intake valves and 2.2 mm (0.086 in.) for exhaust
valves. Refer to section ADDITIONAL INFORMATION1.A, for "Intake and Exhaust Valve"
specifications which are listed in Table 1-38and listed in Table 1-40. See Figure 1-79.
Figure 1-79
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Intake and Exhaust Valve Face Refacing and Rim Width
(Rev. 2004)
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1.4.5.2
Inspection of Valve Springs
Inspect the valve springs and replace any that are pitted or cracked. The entire spring should
be inspected. When a broken spring is replaced, the rotator and valve locks for that valve and
spring should also be replaced.
Use valve spring tester, J 22738-02, to test the springs. See Figure 1-80.
Figure 1-80
Testing Valve Spring
If the spring load is less than 280 N (63 lb) at a compressed length of 67.25 mm (2.648 in.), the
spring should be replaced and the valve locks should be discarded.
1.4.5.3
Inspection of Valve Guides
Inspect the guides for cracks, chipping, scoring or excessive wear.
Measure the valve guide bore with a small hole gage or gage pin, and measure the valve stem
diameter with a micrometer. Compare the measurements to determine valve stem clearance. If the
clearance is greater than 0.152 mm (0.006 in.), the valve guide must be replaced.
1.4.5.4
Inspection of Valve Seat Inserts
Inspect valve seat inserts for wear, cracking or incorrect seat angle, which should be 31 degrees,
standard valve seat insert thickness. See Figure 1-68.
All information subject to change without notice.
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1.4.6
Installation of Intake and Exhaust Valve Seat Insert
Perform the following steps for intake and exhaust valve seat insert installation:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
1. Clean the seat insert counterbores and the new seat inserts with a suitable solvent and
blow dry with compressed air.
2. Use valve seat insert installers, J 33190 (intake) and J 34983 (exhaust), to install new
inserts. See Figure 1-81.
Figure 1-81
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Valve Seat Insert Installation Tools
(Rev. 2004)
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3. Start the insert squarely into its counterbore with the seat facing up. See Figure 1-82.
1. Seat
3. Cylinder Fire Deck
2. Valve Seat Insert
Figure 1-82
Valve Seat Insert Insertion
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4. Pilot the installer into the valve guide from the firedeck surface. See Figure 1-83.
Figure 1-83
Valve Seat Insert Installation
5. Drive the insert solidly into its seat in the cylinder head. See Figure 1-84.
Figure 1-84
1-104
Seating Valve Seat Insert
(Rev. 2004)
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6. Check the concentricity of valve seat with the valve guide using dial indicator, J 8165-2,
and pilot, J 35623-A. See Figure 1-85.
Figure 1-85
[a]
Check Valve Seat Concentricity
If the concentricity is within 0.05 mm (0.002 in.), no grinding is required.
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[b]
If the concentricity is not within 0.05 mm (0.002 in.), grind the seat only enough to
true it up, being sure to lightly grind a full 360 degrees.
NOTE:
Valve seat insert grinding should be limited to light clean-up or concentricity truing. For a
fine, accurate finish, the eccentric grinding method using tool J 7040-A is recommended,
because the grinding wheel contacts the insert at only one point at any time, and a
micrometer feed permits controlled fine adjustment. See Figure 1-86. Seats must be
ground to a 31 degree angle.
Figure 1-86
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Grinding Valve Seat Insert
(Rev. 2004)
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7. The valve head recess depth from the firedeck is increased by valve and/or insert grinding.
It should be checked with a sled gage, J 22273-01 (or equivalent). See Figure 1-87.
Figure 1-87
Measuring Valve Head Recess Depth
[a]
If the diesel intake exhaust valve head recess depth is not between 1.4 to 1.8 mm
(0.055-0.071 in.), the valve and seat must be replaced.
[b]
If the gas intake valve head recess depth is between 0.79 to 1.17 mm (0.031-0.046
in.), the valve and seat are correctly installed.
[c]
If the gas exhaust valve head recess depth is not between 0.976-1.4 mm (0.030-0.053
in.), the intake 0.79-1.17 mm (0.031 -0.046 in.) valve and seat must be replaced for
the Series 60G engine.
8. After light clean-up, thoroughly clean the valve seat with fuel oil and blow dry with
compressed air. Check seat-to-valve face contact by applying a light coat of Prussian Blue
(or equivalent) to the valve seat land. Insert the valve in the guide and "bounce" the valve
head on the seat insert without rotating the valve. A full 360 contact line should appear
approximately centered on the valve face.
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1.4.7
Installation of Valve Guide
Perform the following steps for valve guide installation:
NOTE:
Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasure
craft marine engines.
1. Start the chamfered end of the valve guide into the cylinder head from the top.
See Figure 1-88.
Figure 1-88
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Valve Guide Installation
(Rev. 2004)
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2. Insert the driver into an air chisel. Insert the driver into the valve guide limiting sleeve
J 33191-A and install this assembly over the valve guide. Drive the guide into the cylinder
head until the driver bottoms in the limiting sleeve. See Figure 1-89.
Figure 1-89
Valve Guide Installation
3. Properly used, the installer ensures the correct protrusion of the valve guide from the
cylinder head of 37.75 mm (1.486 in.).
All information subject to change without notice.
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1.4.8
Installation of Valve, Spring, Seal and Rotator
Perform the following steps for valve installation:
1. Position the cylinder head vertically on the overhaul stand. Lubricate the valve stems with
clean engine lubricating oil and slide them into their respective valve guides and against
the valve seats. If reusing valves, install them to their original positions.
2. Install the valve spring seat over the valve guide. Install the valve stem oil seals using
valve stem oil seal installation tools. See Figure 1-90.
1. Valve Stem Seal Installer
4. Valve Guide
2. Oil Seal Protector Cap
5. Valve
3. Valve Spring Seat
6. Valve Stem Oil Seal
Figure 1-90
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Valve Stem Oil Seal Installation Tools
(Rev. 2004)
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3. Check the length of the plastic seal protector cap relative to the lock groove on the valve
stem. If the seal protector cap extends more than 1.6 mm (1/16 in.) beyond the groove,
trim off the excess length of the cap. See Figure 1-91.
Figure 1-91
Oil Seal Protection Cap Sizing
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4. Install the cap over the valve stem. See Figure 1-92.
Figure 1-92
1-112
Oil Seal Protection Cap Installation
(Rev. 2004)
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NOTICE:
Ensure all valve spring seats have been installed before the
valve stem seal is installed.
5. The valve stem oil seal may be installed with or without oil. Push the seal over the
protector. See Figure 1-93.
NOTE:
The valve stem oil seal on the natural gas engine has a larger inside diameter than the
diesel engine. The seal portion of the natural gas oil seal is black in color.
Figure 1-93
Valve Stem Oil Seal Installation
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6. Push the seal down on the valve stem using the seal installer, J 39109, while holding the
valve head against the seal. See Figure 1-94.
Figure 1-94
Valve Stem Oil Seal Installer
7. When the installer tool contacts the cylinder head, the seal is correctly positioned. Be
sure the installer is square against the cylinder head. Remove the seal installer and
protector cap.
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8. Install the valve spring and rotator. See Figure 1-95. If reusing parts, install them to
their original positions.
1. Valve Locks
4. Valve Stem Oil Seal
2. Valve Rotator
5. Valve Guide
3. Valve Spring
6. Valve Spring Seat
Figure 1-95
Valve Spring and Related Parts
9. Using the valve spring compressor tool, J 8062, compress the valve spring only as much
as required to install the valve locks. After installing the valve locks, rap the end of the
valve stem sharply with a plastic mallet to seat the valve locks.
NOTE:
Always install new valve stem locks when installing valves.
NOTE:
Be sure the valve rotator is properly centered and aligned to avoid scoring the valve
stem. Do not compress the spring any more than necessary to install the locks, to avoid
damaging the oil seal.
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10. After all of the valves are installed, check the spring opening pressure on each valve
using spring load gage. See Figure 1-96.
Figure 1-96
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Checking Valve Spring Load
(Rev. 2004)
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11. Note the gage reading when the valve just starts to unseat. The force required to unseat the
valve must not be less than 280 N (63 lb).
12. Remove the cylinder head from the overhaul stand and install it on the engine.
Refer to section 1.2.5.
13. Install the camshaft and rocker arm assemblies. Lightly lubricate the overhead assemblies
with clean engine oil. Refer to section 1.24.5.
14. If the engine is equipped with a Jake Brake®, install the brake. Refer to section 1.30.5.
15. Adjust the valve clearance and injector timing. Refer to section 12.2.
16. If the engine is equipped with a Jake Brake®, lash the brake. Refer to section 12.2.
17. Install any other components that were removed.
18. Fill the engine crankcase (refer to section 13.13.1) with the proper lubricant.
Refer to section 5.2.1.
19. Close any drain cocks that were opened and fill the cooling system.
Refer to section 13.13.4. Purge the air from the system using the vent in the thermostat
housing. Complete filling of the cooling system is essential for proper engine operation.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
20. Start the engine and check for leaks.
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1.5
1.5
ENGINE LIFTER BRACKETS
ENGINE LIFTER BRACKETS
A total of three engine lifter brackets are installed on each Series 60 engine and are utilized when
removing and replacing the engine.See Figure 1-97 and see Figure 1-98.
Figure 1-97
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Lifting Engine
(Rev. 2004)
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Figure 1-98
Lifting Heat Exchanger-Cooled Pleasure Craft Marine Engine
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1.5
ENGINE LIFTER BRACKETS
To avoid injury from a falling engine, do not use the engine
lifter brackets alone when lifting the engine with a marine
gear, main alternator, engine skid, engine module, radiator,
or similar component attached. The engine lifter brackets
are designed to lift the engine only.
NOTICE:
To lift the engine, use a suitable lifting device. See Figure 1-97.
A spreader bar should be used with a sling and adequate chain
hoist when lifting any engine. The lifting device should be
adjusted so the lifting hooks are vertical to prevent bending the
engine lift brackets. To ensure proper weight distribution, all
three engine lift brackets provided must be used in lifting the
engine. Be sure the spreader bar is adequate to prevent lifter
brackets from contacting the engine rocker cover and causing
damage.
A lifter bracket should always be reinstalled whenever removal is necessary. See Figure 1-99
and see Figure 1-100.
1-120
(Rev. 2004)
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Figure 1-99
Engine Lifter Brackets
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1.5
ENGINE LIFTER BRACKETS
1. Left Front Lifter Bracket
3. Rear Lifter Bracket
2. Right Front Lifter Bracket
Figure 1-100
1-122
Pleasure Craft Marine Engine Lifter Brackets
(Rev. 2004)
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On some older installations, the front engine lifter bracket may be integral with the fan support
bracket. See Figure 1-101.
Figure 1-101
Fan Support and Engine Lifter Bracket
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1.5
ENGINE LIFTER BRACKETS
1.5.1
Repair or Replacement of the Lifter Bracket
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-102.
Figure 1-102
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Flowchart for Repair or Replacement of Lifter Bracket
(Rev. 2004)
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1.5.2
Removal and Cleaning of Lifter Bracket
Perform the following steps for lifter bracket removal:
1. Remove the bolts securing the lifter bracket to the engine.
2. On applications with the integral fan support and engine lifter bracket, remove the fan.
Refer to section 1.10.2.
1.5.2.1
Inspection of Lifter Bracket
Perform the following for lifter bracket inspection:
To avoid injury from a falling engine, do not use a damaged
lifter bracket when lifting the engine.
1. Inspect the lifter brackets for cracks, bending or other damage.
2. Replace the bracket if any of these conditions exist.
1.5.3
Installation of Lifter Bracket
Perform the following steps for lifter bracket installation:
1. Install the bracket to the engine. Torque the mounting bolts to 101-126 N·m
(75-93 lb·ft).
2. Install the fan support, heat exchanger support, or charge air cooler support bracket,
refer to section 1.10.3.
All information subject to change without notice.
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1.6
1.6
ROCKER COVER
ROCKER COVER
The rocker cover completely encloses the valve and injector operating mechanism on top of the
cylinder head (and in some cases an engine brake), including the overhead camshaft.
Depending on the installation, the rocker cover may be a one-piece, two-piece or three-piece
design. See Figure 1-104, see Figure 1-105, and see Figure 1-106.
The one-piece rocker cover is molded of a sound-dampening, fiberglass-reinforced, synthetic
material. It is internally ribbed to distribute the hold-down bolt clamp load for effective, full
perimeter sealing. See Figure 1-103.
Effective July 1993, a breather baffle is installed on the low-profile aluminum rocker cover.
NOTE:
Effective May 1999, all Series 60 engines are built with a reusable rocker cover
gasket. This gasket does not need to be replaced at the time of removal provided
there is not any damage observed.
1. Gasket
5. Cover Plug
2. Rocker Cover
6. Bolt
3. Isolator
7. Element
4. Washer
8. Clip
Figure 1-103
1-126
One-piece Rocker Cover - Series 60 Diesel Engine
(Rev. 2004)
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1. Limiting Sleeve
5. Rocker Cover Cap
2. Isolator
6. Diamond-Shaped Seal
3. Washer
7. Rocker Cover Base
4. Bolt
8. Isolator Rim Seal
Figure 1-104
Two-piece Rocker Cover - Series 60 Diesel Engine
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1.6
ROCKER COVER
1. Cylinder Head
4. Bolt
2. Rocker Cover Base
5. Gasket
3. Rocker Cover Cap
6. Isolator Rim Seal
7. Ventilation Fitting
Figure 1-105
1-128
Three-piece Rocker Cover - (Heat Exchanger-Cooled Marine
Engine)
(Rev. 2004)
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1.6
ROCKER COVER
1. Gasket
8. Cover
2. Seal Ring
9. Bolt
3. Tube
10. Isolator
4. Seal Ring
11. Spacer
5. Screw
12. Rocker Cover Base
6. Cover
13. Gasket
7. Bolt
Figure 1-106
1-130
Two Piece Rocker Cover - Series 60G Engine with Coil Over
Plug Ignition
(Rev. 2004)
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The two-piece rocker cover is constructed of cast aluminum. The top piece or cap is held in place
by eight bolts and is removable for access to the valve, engine brake and fuel injector adjusting
mechanisms. A one-piece diamond shaped perimeter seal is located in a groove in the rocker
cover base and seals the cap to the base. See Figure 1-107.
1. Limiting Sleeve
5. Rocker Cover Cap
2. Isolator
6. Diamond-Shaped Seal
3. Washer
7. Rocker Cover Base
4. Bolt
8. Isolator Rim Seal
Figure 1-107
Two-piece Rocker Cover
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1.6
ROCKER COVER
The three-piece rocker cover is similar to the two-piece cover but with an additional intermediate
cover and diamond seal and new cover cap. See Figure 1-108.
1. Limiting Sleeve
6. Rocker Cover Cap
2. Isolator
7. Bolt
3. Washer
8. Intermediate Cover
4. Bolt
9. Rocker Cover Base
5. Bolt
Figure 1-108
Three-piece Rocker Cover
Two caps are available with the Series 60 diesel engines. One is for use with a Jake Brake®, and
one without a Jake Brake®.
Only one cap is available with the Series 60G engines.
The rocker cover base is attached to the cylinder head using ten assemblies consisting of a bolt,
limiter sleeve, isolator and flat washer. All rocker covers use a silicone rim seal, seated in a
groove around the bottom edge of the rocker cover base to provide an effective oil seal. The
one-piece and two-piece design rocker covers incorporate a crankcase ventilation breather outlet.
The three-piece design and the Series 60G cap incorporate a combination filler/breather at the
camshaft cover (gear case cover) position.
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1.6.1
Repair or Replacement of Rocker Cover
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-109.
Figure 1-109
Flowchart for Repair or Replacement of Rocker Cover
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1.6
ROCKER COVER
1.6.2
Removal and Cleaning of One-piece Rocker Cover For Diesel
Engines Only
Preclean the rocker cover, especially around its seat on the head, and in the attaching bolt recesses,
to keep dirt and debris out of the valve gear chamber.
Perform the following steps to remove the one-piece rocker cover:
1. Remove the center plugs, hold-down bolts, washers and isolators.
2. Lift the rocker cover straight up off the engine.
1.6.2.1
Cleaning and Inspection of the One-piece Rocker Cover For
Diesel Engines Only
Inspect the rocker cover as follows:
1. Remove the breather element and retainer clip.
NOTICE:
To avoid damaging the silicone isolators, do not clean them with
mineral spirits, fuel oil or any petroleum based solvents.
2. Remove bolt assemblies and isolators and clean in detergent and water solution.
3. Remove gasket from rocker cover and clean the gasket and rocker cover. Remove
old RTV sealant from the corners of the gasket and clean the gasket and rocker cover
components in clean fuel oil.
NOTE:
Pay special attention to the breather element. Clean thoroughly or replace as required.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
4. Blow dry with compressed air.
5. Clean the breather recess in the rocker cover.
6. Check for damage. Replace as necessary.
7. Reinstall the breather element and retainer clip.
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1.6.3
Removal and Cleaning of Two-piece Rocker Cover For Diesel
Engines Only
Preclean the two piece rocker cover, especially around its seat on the head, and in the attaching
bolt recesses, to keep dirt and debris out of the valve gear chamber.
Perform the following steps to remove the two-piece rocker cover:
1. Remove the eight screws that attach the rocker cover cap to the base.
2. Lift the cap off the base.
3. Loosen and remove the ten bolt and isolator assemblies that attach the base to the cylinder
head.
4. Lift the base straight up off the cylinder head.
1.6.3.1
Inspection of Two-piece Rocker Cover
Perform the following steps to inspect the two-piece valve rocker cover which has a removable
breather housing:
1. Remove the three screws and retainer that retains the breather housing.
2. Remove the breather housing, seal, and wire mesh element.
3. Wash the components in clean fuel oil.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
4. Blow dry with compressed air.
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ROCKER COVER
5. Reassemble breather housing to valve cover cap. See Figure 1-110. Torque the screws to
2.5 N·m (22 lb·in.).
1. Two-Piece Rocker Cover
6. Retainer
2. Retainer Clip
7. Two-piece Low Profile Rocker Cover Cap
3. Wire Mesh Element
8. Seal
4. Screw
9. Breather Housing
5. Retainer Cover
Figure 1-110
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Two-piece Rocker Cover Assembly
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
1.6.4
Removal and Precleaning of Two-Piece Rocker Cover-Gas
Engines with Coil Over Plug Ignition System Only
Preclean the rocker cover, especially around its base on the cylinder head and in the attaching bolt
recesses to keep dirt and debris out of the valve gear chamber.
To remove the two-piece rocker cover:
1. Remove the ignition boots from the spark plug wells. Refer to section 15.3.1.
2. Lift the cap off the base leaving the six extensions tubes in the cylinder head.
3. Blow any excess oil from the outside of the extension tube so that the oil will not enter the
spark plug well when the extensions tubes are removed.
4. Pull the six extension tubes from the cylinder head.
5. Loosen and remove the ten bolt/isolator assemblies that attach the base to the cylinder
head.
6. Lift the base straight up off the cylinder head.
1.6.5
Removal and Cleaning of Three-piece Rocker Cover
Preclean the three-piece rocker cover, especially around its seat on the head, and in the attaching
bolt recesses, to keep dirt and debris out of the valve gear chamber.
Perform the following steps to remove the three-piece rocker cover:
1. Remove the eight screws that attach the rocker cover cap to the intermediate cover.
See Figure 1-108.
2. Lift the cap off the intermediate cover.
3. Loosen and remove the eight bolts that attach the intermediate rail to the base.
4. Lift intermediate off the base.
5. Loosen and remove the ten bolt/isolator assemblies that attach the base to the cylinder
head.
6. Lift the base straight up off the cylinder head.
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ROCKER COVER
Before inspecting the rocker cover, clean the isolators as follows:
NOTICE:
To avoid damaging isolators, do not use solvents of any kind,
or any petroleum distillates to clean them. The isolators can be
cleaned with mild soap and water if necessary. Install new seals
and isolators clean and dry.
1. Wash isolators with mild soap and water.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
2. Be sure to completely dry gasket grooves in the rocker cover with compressed air.
3. Use new gaskets (do not reuse old gaskets).
NOTICE:
Reuse gaskets with manufacturing date after May 28, 1999.
4. Inspect the lower rocker cover base-to-cylinder head gasket for damage replace if gasket
is damaged.
5. If gasket is not damaged clean off excess RTV, clean gasket with clean fuel oil dry
completely and reuse part.
1.6.5.1
Inspection of Three-piece Rocker Cover
Inspect the three-piece valve cover as follows:
1. Wash the components in clean fuel oil.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
2. Blow dry with compressed air.
3. Clean the breather recess in the rocker cover.
4. Check for damage. Replace as necessary.
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SERIES 60 SERVICE MANUAL
1.6.6
Disassembly of Rocker Cover
Disassemble the rocker cover as follows:
1. Disengage the clip that holds the crankcase vent breather element in the valve cover by
pressing the center of the spring steel retaining clip outward and removing the straight end.
2. Rotate the clip upward to remove the curved end.
3. Remove the wire mesh element.
1.6.7
Pre-installation of Rocker Cover
Preform the following steps prior to installing the rocker cover:
1. Install the rocker cover seal in corners of the camshaft cap section (arch at each end
of the valve cover) first.
NOTE:
Be sure the rocker cover grooves and the seals are clean, free of oil and dry.
2. Install the cam cap section, starting in the center, by pushing the seal into the groove at the
top of the arch. Then install each section at its halfway point. Seat the seal completely
around the arch. Be sure the corners are still firmly seated after the arch is completed.
They should present a square corner parallel to the rocker cover rail. Repeat this procedure
for the cam cap section on the other end. See Figure 1-111.
Figure 1-111
Rocker Cover Gasket Installation
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ROCKER COVER
3. Install the long runs of the gasket starting in the center, by pushing the seal into the groove.
4. Then install the rail portion at each halfway point. Repeat this procedure for the other rail
portion. Make sure the seal is completely seated all the way around the valve cover.
NOTE:
The corners must be cleaned prior to RTV installation for best results.
5. Apply a small 4.75 mm (3/16 in.) fillet of RTV in the corners formed by the rear camshaft
cap and the head, where the cover seal contacts. Repeat this procedure for the corners
formed by the front camshaft cap and the head. See Figure 1-112.
Figure 1-112
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RTV Installation
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SERIES 60 SERVICE MANUAL
1.6.8
Installation of One-Piece Rocker Cover
Perform the following steps to install a one-piece rocker cover:
1. Position the rocker cover on the cylinder head.
2. Install the two bolts, with isolators and washers installed, into their recesses in the
one-piece rocker cover.
3. Torque the two bolts, starting with the center bolts and working out, to 20-25 N·m
(15-18 lb·ft).
4. Press the two protective plugs into the two center holes until they are firmly seated.
5. Install any other components that were removed for their procedure.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
6. Start the engine and check for leaks.
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ROCKER COVER
1.6.9
Installation of Two-Piece and Three-Piece Rocker Covers
Perform the following steps to install a two or three-piece rocker cover:
1. Position the rocker cover base on the cylinder head.
2. Lubricate the valve cover limiting sleeves with clean silicone spray. Insert the sleeves into
the isolators until the end of the sleeve is flush with the isolator. See Figure 1-113.
1. Limiting Sleeve
3. Bolt
2. Isolator
4. Flat Washer
Figure 1-113
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Rocker Cover Base Hold Down Hardware
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SERIES 60 SERVICE MANUAL
3. Install the hold-down bolts, with washers installed, to the limiting sleeves.
4. Install the hold-down assemblies to the rocker cover base, and thread the bolts two to three
threads into the cylinder head.
NOTE:
Use care when tightening the rocker cover base hold-down bolts that the injector wires
do not get caught between the limiting sleeve and the cylinder head. See Figure 1-114.
Figure 1-114
Rocker Cover Base Hold-down Bolt Installation
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ROCKER COVER
5. Torque the ten rocker cover base hold-down bolts to 30-38 N·m (22-28 lb·ft).
See Figure 1-115.
NOTE:
Torque the bolts in two stages, using half-torque values first.
Figure 1-115
Rocker Cover Base Bolt Tightening Sequence
6. Be sure the groove in the top of the rocker cover base, and its mating, diamond-shaped
seal are clean and dry. Install the diamond-shaped seal to the groove by pressing the seal
into the groove. Use care not to stretch or twist the seal. The seal has a definite shape, and
should be installed exactly as removed from the base. If the seal cannot be installed to its
groove without bunching or looping, the seal is stretched and must be replaced. The same
procedure applies to the intermediate cover diamond seal installation.
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7. Install the rocker cover cap to the base. Install the eight screws that attach the cap to the
base, and torque to 22-25 N·m (16-18 lb·ft) using the torque sequence. See Figure 1-116.
Tighten the bolts in two stages, using half-torque value first. The same procedure applies
to the intermediate cover installation.
Figure 1-116
Rocker Cover Bolt Tightening Sequence
8. Install any other parts that were removed for this procedure.
9. Refer to section 1.6.8 for the exhaust caution before preceeding. Start the engine and
check for leaks. Shutdown engine after checking for leaks.
All information subject to change without notice.
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1.6
ROCKER COVER
1.6.10
Installation of the Two-Piece Rocker Cover Cap - Diesel Engines
Only
Install the two-piece rocker cover as follows:
1. Be sure the groove in the bottom of the rocker cover base, and its mating, diamond-shaped
seal are clean and dry. Install the diamond-shaped seal to the groove by pressing the seal
into the groove. Use care not to stretch or twist the seal. The seal has a definite shape, and
should be installed exactly as removed from the base. If the seal cannot be installed to its
groove without bunching or looping, the seal is stretched and must be replaced. The same
procedure applies to the intermediate cover diamond seal installation.
2. Install the rocker cover cap to the base. Install the eight bolts that attach the cap to the
base, and torque to 22-25 N·m (16-18 lb·ft) using the torque sequence. See Figure 1-117.
Tighten the bolts in two stages, using half-torque value first. The same procedure applies
to the intermediate cover installation.
Figure 1-117
Rocker Cover Bolt Cap Tightening Sequence
3. Install any other parts that were removed for this procedure.
4. Refer to section 1.6.8 for the exhaust caution before preceeding. Start the engine and
check for leaks. Refer to section 11.8.
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SERIES 60 SERVICE MANUAL
1.6.11
Installation of the Two-Piece Rocker Cover Cap (Gas Engines with
Coil Over Plug Ignition System Only)
Install the two-piece rocker cover cap as follows:
1. Clean any oil or dirt from the spark plug wells.
2. Insert the six extension tubes with O-rings in the cylinder head.
3. Orient the extension tubes so that twelve threaded holes are in a straight line. This will
allow the coil mounting bolts to engage these holes after the rocker cover cap is installed.
4. Place the rocker cover cap on base without disturbing the extension tube seals. Loosely
install the eight bolts that attach the cap to the base.
5. Insert the coils into the spark plug wells. Engage the coil mounting bolts into the extension
tubes. Torque the bolts 13-16 N·m (10-12 lb·ft).
6. Torque the eight rocker cover cap mounting bolts to 22-25 N·m (16-18 lb·ft).
7. Install the remaining ignition system parts. Refer to section 15.2.
8. Apply antiseize compound to the coil cover mounting screw holes to aid removal of
these parts in the future.
9. Install any other parts that were removed for this procedure.
10. Refer to section 1.6.8 for the exhaust caution before preceeding. Start the engine and
check for leaks. Refer to section 11.8.
All information subject to change without notice.
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1.7
1.7
CRANKSHAFT
CRANKSHAFT
The crankshaft is a one-piece forging of chrome-alloy steel, heat-treated to ensure strength and
durability. See Figure 1-118.
NOTE:
The natural gas crankshaft has machined counter weights to allow for shorter rods.
Figure 1-118
Crankshaft
The main and connecting rod bearing journal surfaces and fillets are induction hardened.
Complete static and dynamic balance of the crankshaft has been achieved by counterweights
incorporated in the crankshaft.
Current crankshafts may have a six-bolt or twelve-bolt mounting pattern on the front.
NOTICE:
Do not install iron cylinder kits into engines with "lightweight"
crankshafts.
The piston pin bolts will hit crankshaft
counterweights preventing engine from turning over and
possibly causing engine damage.
NOTE:
Effective May 2001, a new “lightweight” crankshaft is used on 12.7L engines using steel
pistons. (The iron piston pin bolts interefere with the new lightweight crankshaft design.)
See Figure 1-119 and see Figure 1-120.
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Figure 1-119
Current and Former Crankshafts
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1.7
CRANKSHAFT
Figure 1-120
1-150
Varied Piston Dome-Crankshaft Clearances
(Rev. 2004)
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The crankshaft end play is controlled by thrust washers located at the No. 6 main bearing cap
and saddle of the engine. See Figure 1-121.
1. Upper Thrust Washer (2)
5. Dowel
2. Upper No. 6 Bearing Shell
6. No. 6 Main Bearing Cap
3. Lower Bearing Shell (No. 1 through 7)
7. Main Bearing Cap Bolt
4. Lower Thrust Washer (former design only)
Figure 1-121
Crankshaft Thrust Bearing Detail
The current design makes use of thrust washers in the upper positions only.
Oversize thrust washers are available to correct for excessive end play.
All information subject to change without notice.
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CRANKSHAFT
On some engines, the No. 6 main bearing cap is indexed to the cylinder block by two slots in the
cap which register with dowels in the cylinder block. See Figure 1-122.
Figure 1-122
Former No. 6 Main Bearing Cap
The current design does not use the indexing dowels. See Figure 1-123.
Figure 1-123
1-152
Current No. 6 Main Bearing Cap
(Rev. 2004)
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Full pressure lubrication to all connecting rod and main bearings is provided by drilled passages
within the crankshaft and cylinder block. See Figure 1-124.
Figure 1-124
Crankshaft Lubricating Oil Holes
Six or twelve tapped holes, equally spaced, are provided on the rear butt for attaching the flywheel.
There are six or twelve equally spaced tapped holes on the front butt of the crankshaft for attaching
the crankshaft pulley and vibration damper. No locating dowels are provided at either end.
Each standard main bearing journal is 125.000-124.968 mm (4.921-4.920 in.) in diameter and
each standard connecting rod journal is 85.000-84.975 mm (3.346-3.345 in.) in diameter.
All information subject to change without notice.
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1.7
CRANKSHAFT
New crankshafts with smaller radii fillets (listed in Table 1-2) replaced the former crankshafts,
effective with the following engine serial numbers:
Table 1-2
Engine Model
Engine Serial Number
6067WK60 (11.1 L)
6R184522
6067GK60 (12.7 L)
6R188251
New Crankshafts with Smaller Radii Fillets
This change was made to permit installation of new, wider connecting rod bearings that increase
rod bearing oil film thickness and reduce bearing pressures. The fillets on the new crankshafts
have a radius of 4.0-3.5 mm (0.157 -0.138 in.). The fillets on the former crankshafts had a radius
of 6.0-5.5 mm (0.236 -0.216 in.). To conform with this change, new connecting rods with smaller
rod chamfers were also released. Refer to section 1.20for information on the new connecting
rods and bearings.
The new crankshafts, bearings, and connecting rods must be used together to ensure
interchangeability. Former parts cannot be mixed with new parts in the same engine. The former
crankshafts will no longer be available.
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1.7.1
Repair or Replacement of Crankshaft
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-125.
Figure 1-125
Flowchart for Repair or Replacement of Crankshaft
All information subject to change without notice.
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1.7
CRANKSHAFT
1.7.2
Removal and Cleaning of Crankshaft
When removal of the crankshaft becomes necessary, first remove the transmission, then proceed
as follows:
1. Steam clean the exterior of the engine. Refer to section 1.1.3.
2. Drain the cooling system. Refer to section 13.13.4.
3. Drain the lubricating oil. Refer to section 13.13.1.
4. Attach suitable chain hoist and spreader bar with hooks to the three lifter brackets (one at
the front and two at the rear). Remove all engine to base attaching bolts and remove the
engine from its base. Refer to section 1.1.2. See Figure 1-5.
To avoid injury from a falling engine, ensure the engine
is securely attached to the engine overhaul stand before
releasing the lifting sling.
5. Remove and inspect all of the accessories and assemblies with their attaching parts as
necessary to permit the engine block adaptor, to be bolted to the intake (left) side of the
cylinder block. Mount the engine to the overhaul stand, J 29109 with adaptor, J 35635-A
attached. Refer to section 1.1.2.
6. Remove the oil pan, refer to section 3.11.2.
7. Inspect the oil pan, refer to section 3.11.3.1.
8. Remove the lubricating oil pump, refer to section 3.2.2.
9. Inspect the lubricating oil pump, refer to section 3.2.3.1.
10. Remove the flywheel, refer to section 1.14.2.
11. Inspect the flywheel, refer to section 1.14.2.1.
12. Remove flywheel housing, refer to section 1.16.2.
13. Inspect the flywheel housing, refer to section 1.16.2.1.
NOTICE:
Use care when removing the crankshaft pulley as the vibration
damper may come off. If the damper is allowed to fall, damage
to the internal components of the damper may result.
14. Loosen and remove two of the crankshaft pulley retaining bolts and hardened washers
180 degrees apart and install two flywheel guide studs, J 36235, in their place. Then
loosen and remove the remaining four pulley retaining bolts and hardened washers.
Refer to section 1.13.2.
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15. Remove and inspect the viscous vibration damper. Refer to section 1.12.2, and
refer to section 1.12.2.1, for inspection.
16. Remove and inspect the engine front support and gear case cover. Refer to section 1.10.2,
for removal and refer to section 1.10.2.1, for inspection.
17. Remove the cylinder head, refer to section 1.2.2.
18. Inspect the cylinder head, refer to section 1.2.3.1.
19. Loosen and remove the main bearing cap bolts. Remove the main bearing caps for
inspection. Refer to section 1.9.2.
NOTE:
The connecting rod caps must be reinstalled to their respective connecting rods. The
main bearing caps should be kept in sequence, so that they may be installed to their
original positions.
20. Remove and inspect the piston and connecting rod assemblies. Refer to section 1.19.2
for removal and refer to section 1.19.3.1.
21. Remove and inspect the thrust washers from each side of the No. 6 main bearing cap, if
they exist. (Engines with a serial number greater than 6R-6287 do not have thrust washers
on the No. 6 main bearing cap.) Refer to section 1.9.2.2 for inspection.
22. Remove and inspect the crankshaft, including the crankshaft gear and timing wheel.
Refer to section 1.7.2and refer to section 1.7.2.1.
23. Remove the timing gear and timing wheel, refer to section 1.22.2and inspect it,
refer to section 1.22.3.
24. Remove the Woodruff key from the slot in the front crankshaft hub.
1.7.2.1
Inspection of Crankshaft
Perform the following steps for crankshaft inspection:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
1. Clean out the oil passages thoroughly with a stiff wire brush. Clean the crankshaft with
fuel oil and dry it with compressed air.
2. Inspect the crankshaft timing gear keyway for evidence of cracks or wear. Replace the
crankshaft if these conditions are evident.
3. If the crankshaft shows evidence of excessive overheating, replace the crankshaft since the
heat treatment has probably been destroyed.
All information subject to change without notice.
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CRANKSHAFT
4. Check the crankshaft journal surfaces for score marks and other imperfections. If
excessively scored, the journal surfaces must be reground. Refer to section ADDITIONAL
INFORMATION 1.A, "Main and Connecting Rod Journals".
5. Carefully, inspect the front and rear end of the crankshaft in the area of the oil seal contact
surface for evidence of a rough or grooved condition. Any imperfections of the oil seal
contact surfaces will result in oil leakage at these points.
6. If the crankshaft oil seal contact surfaces are grooved, the seal surfaces must be sleeved
and an oversized seal used. Refer to section 1.8.2.
7. Check the crankshaft thrust surfaces for excessive wear or grooving. If excessively
worn, the thrust surfaces must be reground. Refer to section ADDITIONAL
INFORMATION1.A, "Machining Operations".
8. Check the crankshaft timing gear for worn or chipped teeth. Inspect the timing wheel for
bent or otherwise damaged teeth. Replace as necessary. Refer to section 1.28.2.1.
9. Check the crankshaft journal run-out. Refer to section 1.7.2.4.
10. Check the journal alignment. Refer to section 1.7.2.3.
11. Check the journal measurements. Refer to section 1.7.2.4.
12. Inspect the crankshaft for cracks. Refer to section 1.7.2.1.
1.7.2.2
Crankshaft Journal Run-out Measurements
Support the crankshaft on its front and rear journals on V-blocks or the inverted engine block
with only the front and rear upper bearing shells in place. Check the intermediate main journals
with a dial indicator for run-out when the crankshaft is rotated.
When checking the crankshaft bow, if the run-out is greater than that listed in Table 1-3, the
crankshaft must be replaced.
Journals Supported On
Journals Measured
Maximum Run-out (Total
Indicator Reading)
No. 1 and No. 7
No. 2 and No. 6
0.076 mm (0.003 in.)
No. 1 and No. 7
No. 3 and No. 5
0.127 mm (0.005 in.)
No. 1 and No. 7
No. 4
0.152 mm (0.006 in.)
Table 1-3
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Crankshaft Bow
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SERIES 60 SERVICE MANUAL
1.7.2.3
Adjacent Journal Alignment
When run-out on the adjacent journals is in opposite directions, the sum must not exceed 0.076
mm (0.003 in.) total indicator reading. When the high spots of run-out on the adjacent journals are
in the same direction, the difference must not exceed 0.076 mm (0.003 in.) total indicator reading.
1.7.2.4
Journal Diameter Measurements
Measure all of the main and connecting rod bearing journal diameters. See Figure 1-126.
Figure 1-126
Dimensions of Crankshaft Journals
Measure the journals at several places on the circumference so that taper, out-of-round and
bearing clearances can be determined. If the crankshaft is worn so that the maximum connecting
rod or main bearing journal-to-bearing shell clearance (with new shells) exceeds 0.1270 mm
(0.005 in.) (connecting rod journals) or 0.1422 mm (0.0056 in.) (main bearing journals), the
crankshaft must be reground. Measurements of the crankshaft should be accurate to the nearest
0.0025 mm (0.0001 in.). Also, if the main bearing journal taper of a used crankshaft exceeds
0.0381 mm (0.0015 in.) or the out-of-round is greater than 0.0254 mm (0.001 in.) the crankshaft
must be reground. Specifications for the crankshaft are listed in Table 1-23.
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Also, measure the distance between crankshaft thrust washer surfaces. See Figure 1-127.
Figure 1-127
1.7.2.5
Dimensions for No. 6 Main Bearing Journal Thrust Width
Inspection for Cracks
Carefully check the crankshaft for cracks which start at an oil hole and follow the journal surface
at an angle of 45 degrees to the axis. Any crankshaft with such cracks must be replaced. Several
methods of determining the presence of minute cracks not visible to the eye are available:
refer to section 1.7.2.6, for magnetic particle method, refer to section 1.7.2.7, for fluorescent
magnetic particle method, or refer to section 1.7.2.8, for fluorescent penetrant method.
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SERIES 60 SERVICE MANUAL
1.7.2.6
Magnetic Particle Method
Magnetize the crankshaft and then cover it with a fine magnetic powder or solution. The
crankshaft must be demagnetized after the test to avoid engine damage.
NOTICE:
Very fine cracks may be missed using the magnetic particle
method, especially on discolored or dark surfaces. They will be
disclosed under the black light. If the crankshaft is discolored or
has dark surfaces, the magnetic particle method should not be
used. Refer to section 1.7.2.7for suitable alternate method.
Flaws, such as cracks, form a small local magnet which causes the magnetic particles in the
powder or solution to gather there, effectively marking the crack.
1.7.2.7
Fluorescent Magnetic Particle Method
This method is similar to the magnetic particle method, but is more sensitive since it employs
magnetic particles which are fluorescent and glow under black light. Refer to section 1.7.2.6.
1.7.2.8
Fluorescent Penetrant Method
This is a method which may be used on both non-magnetic and magnetic materials. A highly
fluorescent liquid penetrant is applied to the part. Then the excess penetrant is removed from
the surface and the part is dried. A developing powder is then applied which helps to draw the
penetrant out of the flaws by capillary action. Inspection is carried out under a black light.
A majority of indications revealed by the above inspection methods are normal and harmless and
only in a small percentage of cases is reliability of the part impaired when indications are found.
Since inspection reveals the harmless indications with the same intensity as the harmful ones,
detection of the indications is but a first step in the procedure. Interpretation of the indications
is the most important step.
All crankshafts are magnetic particle inspected after manufacture to ensure against any shafts
with harmful indications getting into the original equipment or factory parts stock.
Crankshaft failures are rare and when one cracks or breaks completely, it is very important to
make a thorough inspection for contributory factors. Unless abnormal conditions are discovered
and corrected, there will be a repetition of the failure.
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CRANKSHAFT
There are two types of loads imposed on a crankshaft in service: a bending force and a twisting
force. The design of the shaft is such that these forces produce practically no stress over
most of the surface. Certain small areas, designated as critical areas, sustain most of the load.
See Figure 1-128.
Figure 1-128
1.7.2.9
Critical Crankshaft Loading Zones
Bending Fatigue
Failures can result from bending of the crankshaft.
The crankshaft is supported between each of the cylinders by a main bearing and the load
imposed by the gas pressure on top of the piston is divided between the adjacent bearings. An
abnormal bending stress in the crankshaft, particularly in the crank fillet, may be a result of
misalignment of the main bearing bores, improperly fitted bearings, bearing failures, a loose or
broken bearing cap, or unbalanced pulleys. Also, drive belts which are too tight will impose a
bending load upon the crankshaft.
Failures resulting from bending start at the pin fillet and progress throughout the crank cheek,
sometimes extending into the main journal fillet. If main bearings are replaced due to one or more
badly damaged bearings, a careful inspection must be made to determine if any cracks have started
in the crankshaft. These cracks are most likely to occur on either side of the damaged bearing.
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1.7.2.10
Torsional Fatigue
Failures result from torsional vibration which takes place at high frequency. A combination of
abnormal speed and load conditions may cause the twisting forces to set up a vibration, referred to
as torsional vibration, which imposes high stresses at the locations. See Figure 1-129.
Figure 1-129
Crankshaft Fatigue Cracks
Torsional stresses may produce a fracture in either the connecting rod journal or the crank cheek
in the rear. Torsional failures may also occur at the front end of the crankshaft at the crankshaft
timing gear drive key slot. Connecting rod journal failures are usually at the fillet or oil hole at
45 degrees to the axis of the shaft.
A loose, damaged or defective vibration damper, a loose flywheel or the introduction of improper
or additional pulleys or couplings are usual causes of this type of failure. Also, overspeeding
of the engine or overriding the engine electronic control system to allow engine overspeeding
may be contributory factors.
1.7.2.11
Crankshaft Cracks
As previously mentioned, most of the indications found during inspection of the crankshaft are
harmless. The two types of indications to look for are circumferential fillet cracks at the critical
areas and 45 cracks (45 to the axis of the shaft) starting from either the critical fillet locations
or the connecting rod journal holes. See Figure 1-129. Replace the crankshaft when cracks of
this nature are found. Refer to section 1.7.3.
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CRANKSHAFT
1.7.2.12
Crankshaft Grinding
The use of properly remanufactured crankshafts is very important to maximize crankshaft main
and connecting rod bearing life.
Remanufactured crankshafts must conform to specifications. See Figure 1-129. The dimensional
requirements for journal axial profile, radial chatter and oil hole washout require confirmation
with a Gould 1200 Surface Analyzer (or equivalent). Information on Gould 1200 is available in
the "Glossary". Refer to section ADDITIONAL INFORMATION1.A.
NOTE:
Visual inspection cannot be relied upon to confirm the compliance to journal quality
specifications.
The procedure of crankshaft journal polishing can easily create axial profile and oil hole washout
conditions beyond specifications. Any polishing operation should be followed by Gould
1200 (or equivalent) measurements to assure conformance to remanufactured specifications.
Refer to section ADDITIONAL INFORMATION1.A, "Crankshaft Remanufactoring Procedures".
All used crankshafts that have not been reground must meet the dimensional specifications
standard or be reground to specifications. Refer to section ADDITIONAL INFORMATION1.A,
"Crankshaft Remanufactoring Procedures".
In addition to standard size crankshaft thrust washers, 0.127 mm (0.005 in.) and 0.254 mm (0.010
in.) oversize thrust washers are available. Thrust surface specifications are listed in Table 1-23.
Remanufactured crankshafts should be stamped on the edge of the No. 1 crank throw
(counterweight) with the appropriate undersize dimensions for identification purposes.
NOTE:
Crankshaft main bearing journals and/or connecting rod journals which exhibit
discoloration due to excessive overheating from bearing failure are NOT acceptable
for rework.
If one or more main or connecting rod journals require grinding, grind all of the main journals
or all of the connecting rod journals to the same required size.
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SERIES 60 SERVICE MANUAL
1.7.3
Installation of Crankshaft
Install the crankshaft using the following procedure:
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
1. Steam clean it to remove the rust preventive and blow out the oil passages with
compressed air.
2. Install the upper main bearing shells in the block. If the old bearing shells are to
be used again, install them in the same locations from which they were removed.
Refer to section 1.9.3.
NOTE:
When a new or reground crankshaft is installed, ALL new main and connecting rod
(upper and lower) bearing shells and new thrust washers must also be installed.
NOTE:
If the crankshaft surfaces were reground, it may be necessary to install oversize thrust
washers on one or both sides of the No. 6 main journal. See Figure 1-121.
3. Install the thrust washer upper halves in the counterbores on either side of the No. 6
bearing saddle. Coat the backs of the thrust washers (without oil grooves) with petroleum
jelly and stick them in place with the oil-grooved sides facing away from the saddle.
4. Apply clean engine oil 360 degrees around all crankshaft bearing journals and install the
crankshaft in place so that the timing marks on the crankshaft timing gear and the bull
gear are aligned. Refer to section 1.22.2.1.
NOTE:
If timing gear and timing wheel were removed install timing gear and timing wheel prior
to installation of crankshaft. Refer to section 1.28.3.
NOTE:
It may be easier to remove the bull gear assembly and re-time the engine.
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CRANKSHAFT
5. Install the main bearing shells in the main bearing caps as follows:
NOTE:
Whether the engines were built with or without thrust washers in the No. 6 main bearing
cap, they are no longer required; they do not need to be reinstalled.
[a]
Align the tang on the lower main bearing shell with the groove in the main bearing
cap. Install the bearing shell to the main bearing cap.
NOTE:
The main bearing caps are bored in position and stamped with position number. They
must be installed in their original positions, with the marked (numbered) side of each
cap toward the cooler (right) side of the cylinder block.
[b]
If the old bearing shells are to be used again, install them in the same bearing caps
from which they were removed.
6. Install the main bearing caps together with lower bearing shells in place.
Figure 1-130
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Main Bearing Cap Installation
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SERIES 60 SERVICE MANUAL
7. Apply a small quantity of International Compound #2® (or equivalent) to the bolt threads
and underside of the bolt heads. Install the main bearing cap bolts and draw them up
snug. See Figure 1-130. Rap the main bearing caps sharply with a fiber mallet or plastic
hammer to insure the caps are fully seated.
8. Torque all of the main bearing cap bolts to 470-530 N·m (347-391 lb·ft). Begin at the
center caps and work progressively toward each end. Tighten the bolts to half the specified
torque and then repeat the tightening sequence to the torque limit.
NOTE:
If the bearings have been installed properly, the crankshaft will turn freely with all of the
main bearing cap bolts drawn to the specified torque.
9. Check the crankshaft end by moving the crankshaft toward the gage with a small 304.8
mm (less than 12 in.) pry bar. See Figure 1-131. Keep a constant pressure on the pry bar
and zero the pointer on the dial indicator. Then, remove and insert the pry bar on the other
side of the bearing cap. Force the crankshaft in the opposite direction and note the amount
of end play on the dial. The end play should be 0.099-0.419 mm (0.0039 -0.0165 in.).
Insufficient end play can be the result of a misaligned No. 6 main bearing, a misaligned
upper thrust washer or a burr or dirt on the inner face of one or more of the thrust washers.
Figure 1-131
Measuring Crankshaft End Play
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CRANKSHAFT
10. Assemble the timing wheel and crankshaft gear on the crankshaft. Refer to section 1.28.3.
11. Install the piston and connecting rod assemblies. Refer to section 1.19.5. Torque the
connecting rod cap nuts to 160-185 N·m (118-137 lb·ft).
12. Install the cylinder head. Refer to section 1.2.5.
13. Install the flywheel housing. Refer to section 1.16.3.
14. Replace the rear crankshaft seal with new seal and sleeve assembly. Refer to section 1.8.7.
15. Install the flywheel. Refer to section 1.14.3.
16. Install the lubricating oil pump, inlet and outlet pipes. Refer to section 3.2.6.
17. Install the gear case cover and engine front support. Refer to section 1.10.3.
18. Replace the front crankshaft seal with new seal and sleeve assembly. Refer to section 1.8.7.
19. Install the viscous vibration damper. Refer to section 1.12.3.
20. Install the crankshaft pulley. Refer to section 1.13.3.
21. Install the oil pan. Refer to section 3.11.4.
22. Use a chain hoist and spreader bar with hooks attached to the lifting brackets at each end
of the engine and remove the engine from the overhaul stand. See Figure 1-5.
23. Remove the overhaul stand adaptor plate from the engine block. See Figure 1-7.
24. Install any accessories that were removed.
25. Install the engine to the equipment from which it was removed.
26. Fill the cooling system. Refer to section 13.13.4.
27. Fill the engine crankcase to correct operating level. Refer to section 13.13.1.
28. After replacing the main or connecting rod bearings or installing a new or reground
crankshaft, operate the engine as outlined in the "Run-In Schedule." Refer to section
11.8.3.2.
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SERIES 60 SERVICE MANUAL
1.8
CRANKSHAFT OIL SEALS
An oil seal is used at each end of the crankshaft to retain the lubricating oil in the crankcase. The
sealing lips of the crankshaft oil seals are held firmly, but not tight, against the crankshaft sealing
surfaces by a spring, thus preventing oil from escaping from the engine crankcase.
A unidirectional laydown-lip crankshaft oil seal, with a dust lip, is used at the front of the
crankshaft. The rear oil seal is pressed into the flywheel housing. With dry flywheel housings,
a single Teflon-lip seal is used. With wet flywheel housings, a two-lip, laydown type seal is
used. See Figure 1-132 and see Figure 1-133.
Figure 1-132
Crankshaft Rear Oil Seal
NOTICE:
Failure to use the required seal in a dry or wet flywheel housing
environment may result in seal damage and oil leakage.
A unidirectional, single Teflon lip seal with an integral dust lip is used at the rear of engines
with dry flywheel housings.
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1.8
CRANKSHAFT OIL SEALS
The Chicago Rawhide® unitized front oil seal is pressed into the gear case cover after the cover is
installed. See Figure 1-133.
Figure 1-133
Crankshaft Front Oil Seal
The seal element runs against a wear sleeve which is an integral part of the seal assembly for
the Chicago Rawhide seal.
Teflon® is a registered trademark of E.I. DuPont de Nemours and Company, Inc.
Chicago Rawhide® is a registered trademark of CR Industries.
The lip of the seals bears against the crankshaft hub surface.
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1.8.1
Repair or Replacement of Oil Seal
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-134.
Figure 1-134
Flowchart for Repair or Replacement of Crankshaft Oil Seal
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1.8
CRANKSHAFT OIL SEALS
1.8.2
Removal of Front and Rear Crankshaft Oil Seal
The rear crankshaft oil seals can be removed with either the flywheel housing installed or removed.
The front crankshaft seal can be removed with the front gear case housing removed or installed.
NOTICE:
Due to the possibility of damage to the crankshaft oil seals, any
time the gear case cover or flywheel housing is removed from
the engine, the crankshaft oil seals must be replaced.
1. Remove the crankshaft oil seal as follows:
[a]
If the gear case housing is removed, refer to section 1.8.3.
[b]
If the gear case housing is installed, refer to section 1.8.4.
2. For the flywheel housing seal, refer to section 1.8.5.
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1.8.3
Removal of Front Crankshaft Oil Seal (Gear Case Housing
Removed)
The Federal Mogul® front crankshaft oil seal may be removed with the gear case housing
removed from the engine.
Perform the following steps if the gear case housing is removed from the engine.
NOTE:
The crankshaft oil seals must be removed if the gear case housing has been removed
from the engine.
1. Support the outer face of the gear case housing on wood blocks.
2. Drive the oil seal out with a brass drift and hammer. Clean the seal bore in the housing.
See Figure 1-135.
Figure 1-135
Front Crankshaft Oil Seal Removal
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CRANKSHAFT OIL SEALS
1.8.4
Removal of Front Crankshaft Oil Seal (Gear Case Housing Still
Installed)
The front crankshaft oil seal may be taken out without removing the gear case housing. This may
be done by using oil seal removal tool J 41329 part of J 35993.
NOTE:
Before proceeding, determine if seal to be removed is Federal Mogul or Chicago
Rawhide brand. Remove and clean all rust and dirt from the crankshaft surface.
Remove Federal Mogul seal as follows:
1. Install puller, J 41329 part of J 35993, over crankshaft and hold against seal.
See Figure 1-136.
2. Using variable speed drill motor and 5/32" bit, drill through outer and inner case of
seal using smallest hole "A" as a guide.
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3. Without moving J 41329 part of J 35993, drill two additional "A" holes equally spaced.
NOTE:
All six holes may be drilled if using three holes proves unsuccessful in pulling seal.
Figure 1-136
Removing Front Crankshaft Oil Seal from Gear Case Cover
4. Rotate J 41329 part of J 35993 clockwise until the "B" holes align with drilled holes
and install sheet metal screws.
5. Apply thread lubricant, J 23444-A part of J 35686, to forcing screw and remove seal.
6. Remove the sheet metal screws from the tool. Discard the oil seal.
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CRANKSHAFT OIL SEALS
7. Remove oil sleeve using crank oil sleeve remover, J 37075-A. See Figure 1-137.
Figure 1-137
Oil Seal Sleeve Removal Tool for the Federal Mogul Seal
NOTE:
Crocus cloth may be used to clean up the high spots from the surface of the crankshaft.
Clean the crankshaft contact surface thoroughly.
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Remove the Chicago Rawhide seal as follows:
Chicago Rawhide® is a registered trademark of CR Industries.
1. Install puller, J 41329 part of J 35993, over crankshaft and hold against seal.
See Figure 1-138.
Figure 1-138
Removing Front Crankshaft Oil Seal from Gear Case Cover
2. Using variable speed drill motor and 5/32 in. bit, drill through outer and inner case of
seal using smallest hole "A" as a guide.
3. Without moving J 41329 part of J 35993, drill two additional "A" holes equally spaced.
NOTE:
All six holes may be drilled if using three holes proves unsuccessful in pulling seal.
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1.8
CRANKSHAFT OIL SEALS
4. Rotate J 41329 part of J 35993 clockwise until the "B" holes align with drilled holes
and install sheet metal screws.
5. Apply thread lubricant, J 23444-A part of J 35686, to forcing screw and remove seal.
NOTE:
If seal is difficult to remove, there is probably debris on the crankshaft preventing the
wear sleeve from passing over the crankshaft. Push the seal in 1/8", clean crankshaft
surface thoroughly and repeat the removal procedure.
6. Remove the sheet metal screws from the tool. Discard the oil seal.
1.8.5
Removal of Rear Crankshaft Oil Seal (Flywheel Housing Installed)
The rear crankshaft oil seal may be taken out without removing the flywheel housing. This may
be done by using oil seal removal tool, J 41329 part of J 35993.
1. To replace the rear oil seal, with transmission removed, remove the flywheel.
Refer to section 1.14.2.
NOTE:
Before proceeding, determine if seal to be removed is Federal Mogul® or CR brand.
Remove and clean all rust and dirt from the crankshaft surface.
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Remove the Federal Mogul seal as follows:
1. Install puller, J 41329 part of J 35993, over crankshaft and hold against seal.
2. Using variable speed drill motor and 5/32" bit, drill through outer and inner case of seal
using smallest hole "A" as a guide. See Figure 1-139.
Figure 1-139
Rear Oil Seal Removal
3. Without moving J 41329 part of J 35993, drill two additional "A" holes equally spaced.
NOTE:
All six holes may be drilled if using three holes proves unsuccessful in pulling seal.
4. Rotate J 41329 part of J 35993 clockwise until the "B" holes align with drilled holes
and install sheet metal screws.
5. Apply thread lubricant, J 23444-A part of J 35686, to forcing screw and remove seal.
6. Remove the sheet metal screws from the tool. Discard the oil seal.
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1.8
CRANKSHAFT OIL SEALS
Remove the CR seal as follows:
1. Install puller, J 41329 part of J 35993, over crankshaft and hold against seal.
2. Using variable speed drill motor and 5/32" bit, drill through outer and inner case of seal
using smallest hole "A" as a guide. See Figure 1-140.
Figure 1-140
Rear Oil Seal Removal
NOTE:
All six holes may be used if using three holes proves unsuccessful in pulling seal.
3. Apply thread lubricant J 23444-A part of J 35686 to forcing screw and remove seal.
NOTE:
If seal is difficult to remove, push seal in 1/8 in., clean crankshaft surface thoroughly and
repeat the removal procedure.
4. Remove the sheet metal screws from the tool. Discard the oil seal.
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SERIES 60 SERVICE MANUAL
1.8.6
Removal of Rear Oversized Crankshaft Seal with Wear Sleeve
If seal removed is an oversized seal with wear sleeve, the old wear sleeve must also be removed
as follows:
1. To remove a worn wear sleeve, use crank shaft wear sleeve remover, J 37075-A.
See Figure 1-141.
[a]
Install hardened steel sleeve removal tool into flywheel housing bore. Using socket
and breaker bar, rotate tool in three different locations, 2, 4, and 8 o'clock positions,
to score the sleeve, until sleeve stretches sufficiently so it can be slipped off the
end of the crankshaft.
[b]
Crocus cloth may be used to clean up the high spots from the surface of the
crankshaft. Clean the crankshaft. Clean the crankshaft contact surface thoroughly.
Figure 1-141
Rear Oil Seal Wear Sleeve Removal
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1.8
CRANKSHAFT OIL SEALS
1.8.7
Installation of Front and Rear Crankshaft Oil Seal and Wear Sleeve
Install the front oil seal as follows:
An oil seal sleeve, integral to the seal assembly, is pressed onto the end of the crankshaft and
provides a replacement wear surface at the point of contact with the oil seal. The sleeve and
seal are supplied assembled. The assembly is installed using the crankshaft oil seal and sleeve
installation tool. The Federal Mogul® oil seal is installed using tool,J 35686-A, with collar
J 35686-10. The Chicago Rawhide® (CR) oil seal is installed using J 35686-B, but uses collar
J 35686-20. See Figure 1-142 and see Figure 1-143.
1. Washer
3. Crankshaft Seal
2. Washer
Figure 1-142
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Front Crankshaft Oil Seal and Sleeve Installation Tool Set
(Rev. 2004)
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1. Thrust Plate
5. Gear Case/Flywheel Housing
2. Wrench Flat 1/2 in., Guide Stud
6. Crankshaft
3. 3/4 - 10 Hex Nut
7. Guide Stud Retainer (O-ring)
4. Seal and Wear Sleeve Assembly
Figure 1-143
Front Crankshaft Oil Seal
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1.8
CRANKSHAFT OIL SEALS
Install an oversize oil seal and sleeve, as follows:
1. Install the new, oversize oil seal and wear sleeve assembly to the housing.
NOTE:
The assembly used in dry flywheel housings has a unidirectional, lip type Teflon inner
sealing lip and a forward facing Teflon dust lip. The assembly used in wet flywheel
housings has a double-lip seal with unidirectional inner and outer laydown type Teflon
sealing lips.
2. Add new adapter ring and spacers. Do not separate the two.
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Perform the following steps to install the rear oil sleeve:
NOTE:
Rear oil seals have a color code of green for engines built after 6R491683.
NOTE:
The assembly used in dry flywheel housing has unidirectional, lip type Teflon inner sealing
lip and a forward facing Teflon dust lip. The assembly used in wet flywheel housings has
a double-lip seal with unidirectional inner and outer laydown type Teflon sealing lips.
1. Install the two guide studs, J 35686-2, through the holes provided in the base, J 35686-1,
and into two of the tapped holes in the crankshaft, 180 degrees apart. See Figure 1-144.
Tighten the guide studs using the appropriate wrench on the flats of the studs. The base
must be tight against the end of the crankshaft.
1. Washer
3. Crankshaft Seal
2. Washer
Figure 1-144
Rear Oil Seal Installation
All information subject to change without notice.
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1.8
CRANKSHAFT OIL SEALS
2. For rear crankshaft oil seal installations only, install spacer and J 35686-11, to the center
screw of the base. See Figure 1-145 and see Figure 1-143.
Figure 1-145
1-186
Rear Oil Seal Installation
(Rev. 2004)
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3. Install the rear housing and adapter ring with seal and sleeve assembly in place on the
guide studs. See Figure 1-146.
Figure 1-146
Rear Oil Seal and Sleeve Installation
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1.8
CRANKSHAFT OIL SEALS
4. Install the thrust bearing tool with the case side toward the installer housing. Install the
hex nut to the center screw of the base. See Figure 1-147.
Figure 1-147
1-188
Thrust Bearing Installation
(Rev. 2004)
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SERIES 60 SERVICE MANUAL
5. Tighten the hex nut by hand until all the slack is taken up. Use a ratchet and socket to
tighten the hex nut, and install the wear sleeve to the crankshaft and the oil seal to the
flywheel housing and/or gear case cover. See Figure 1-148.
Figure 1-148
Oil Seal and Sleeve Installation
6. When the inside surface of the housing is seated against the base (spacers on rear oil seal
installation), the seal and sleeve are properly positioned and installed.
All information subject to change without notice.
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1.9
CRANKSHAFT MAIN BEARINGS
CRANKSHAFT MAIN BEARINGS
The crankshaft main bearing shells are precision made and are replaceable without machining.
They consist of an upper bearing shell seated in each cylinder block main bearing support and a
lower bearing shell seated in each main bearing cap. See Figure 1-149.
1. Upper No. 6 Thrust Washers
8. Main Cap No. 1, 2, 3, 4, 5 & 7
2. Crankshaft
9. Lower Thrust Bearing Shell
3. Lower No. 6 Thrust Washers
10. Woodruff Key
4. Lower No. 6 Thrust Bearing Shell
11. Upper Thrust Bearing Shell No. 1, 2, 3, 4, 5 & 7
5. Washer
12. Cylinder Block
6. Bolt
13. Upper No. 6 Thrust Bearing Shell
7. No. 6 Main Cap
Figure 1-149
1-190
Main Bearing Caps, Bearing Shells and Crankshaft Thrust
Washers
(Rev. 2004)
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The upper and lower bearing shells are located in the respective block and bearing cap by a
tang. The tang is located at the parting line at one end of each bearing shell. The tangs are
offset from center to aid correct insertion. Bearing shell sets are supplied as a matched assembly
and should not be mixed.
A hole in each upper bearing shell registers with a vertical oil passage in the cylinder block.
Lubricating oil, under pressure, passes from the cylinder block oil gallery by way of the bearing
shells to the drilled passage in the crankshaft, then to the connecting rods and connecting rod
bearings. The upper bearing shell is also grooved.
The lower main bearing shells have no oil holes or grooves. Therefore, the upper and lower
main bearing shells must not be interchanged.
All information subject to change without notice.
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CRANKSHAFT MAIN BEARINGS
Thrust washers on each side of the No. 6 main bearing absorb the crankshaft thrust. The
two-piece washers utilize locking tangs that register with locating notches in the bearing shell.
See Figure 1-150.
1. Upper Thrust Washer (2)
4. No. 6 Main Bearing Cap
2. Upper No. 6 Bearing Shell
5. Bolt
3. Lower No. 6 Bearing Shell
Figure 1-150
No. 6 Thrust Bearing Detail
The condition of the lower bearing shells may be observed by removing the main bearing caps.
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1.9.1
Repair or Replacement of Crankshaft Main Bearings
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-151.
Figure 1-151
Flowchart for Repair or Replacement of Crankshaft Main
Bearings
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1.9
CRANKSHAFT MAIN BEARINGS
1.9.2
Removal of Main Bearing Shells
The main bearing caps are numbered consecutively, indicating their respective positions. When
removed, the bearing caps (and the bearing shells, if they are to be reinstalled) must always be
reinstalled in their original position.
1. Drain the oil pan, refer to section 13.13.1and remove the oil pan to expose the main
bearing caps refer to section 3.11.2.
2. Remove the oil pump pickup and outlet pipes, and the oil pump. Refer to section 3.2.2.
3. Remove one bearing cap at a time and inspect the lower bearing shell.
Refer to section 1.9.2.2.
NOTE:
If shims are used between the oil pump and the cylinder block, save the shims so that
they can be reinstalled in exactly the same location as removed. The shims are used to
adjust the crankshaft timing gear-to-oil pump drive gear lash.
4. To remove the upper main bearing shells without crankshaft removal, it will be necessary
to use the main bearing shell remover and installer tool set, J 36187. See Figure 1-152.
NOTE:
Remove and reinstall both upper and lower bearing shells for each main journal being
inspected before moving on to the next main journal. Never remove more than one main
bearing cap at a time except for No. 6 and No. 7.
Figure 1-152
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Main Bearing Shell Remover and Installer Tool Set
(Rev. 2004)
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5. To bar the engine over, use the square hole in the middle of the crankshaft pulley, to
position the crankshaft throw. Position the crankcase throw for the main bearing being
worked on so that the oil delivery hole is pointing upward. See Figure 1-153.
Figure 1-153
Roll Pin Hole Installation
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CRANKSHAFT MAIN BEARINGS
6. Install the roll pin to the oil delivery hole in the crankshaft journal. See Figure 1-153. If
this operation is being performed in-frame, use petroleum jelly to retain the roll pin in
the hole.
7. For the No. 6 main bearing journal, it will be necessary to install the lower main bearing
thrust washers (previously removed) to the machined faces of the body from the tool kit.
Stick the thrust washers to the main cap using petroleum jelly. Index the locating tangs on
the thrust washers with the cutouts on the bearing shell. See Figure 1-154.
Figure 1-154
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Upper Main Bearing Shell Removal-Tool Set-Up
(Rev. 2004)
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8. Using the main bearing cap bolts and washer removed from the engine, install the
assembled main bearing cap remover and installer tool to the main bearing saddle being
worked on. The word "Front" stamped on the tool must face the front of the engine. Be
sure that the roll pin in the oil delivery hole registers with the cutout section of the bearing
shell tool before tightening the main bearing cap bolts. See Figure 1-155.
Figure 1-155
Upper Main Bearing Shell Remover Tool Installation
NOTE:
Only the No. 6 main bearing shell requires use of the thrust washers on the sides of
the remover tool. For main bearings No. 1, 2, 3, 4, 5, and 7, it will not be necessary
to install the thrust washers to the tool.
9. Torque the main bearing cap bolts until they are snug 13-27 N·m (10-20 lb·ft).
10. Using the square hole in the middle of the crankshaft pulley, bar the engine over in a
clockwise direction when viewed from the front, approximately 180 degrees until the tang
of the upper main bearing contacts the block. This will roll the bearing shell tool (and the
thrust washers for No. 6 main bearing) into the upper main bearing saddle.
NOTE:
Keep all bearing shells and thrust washers segregated by number, so that they may be
reinstalled exactly as removed if the bearing shells are reused. Shells and washers may
be marked with a permanent marker or equivalent. Do not punch mark or otherwise
disturb the surface of the shells and washers to mark them.
11. Remove the main bearing cap tool from the saddle.
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12. Remove the upper shell (and two thrust washers when working on No. 6 main) from
the tool.
13. Inspect the bearing shells (and thrust washers for No. 6 main). Refer to section 1.9.2.2.
14. Install the upper main bearing to be used, in the main bearing installer and remover with
the word "Front" facing the front of the engine. If the No. 6 main bearing is being done,
install the thrust washers to the bearing. Refer to step 7 in this procedure.
15. Position the remover and installer with the bearings in the saddle being worked on and
install the main bearing cap bolts and washers. Torque the bolts until they are snug 13-27
N·m (10-20 lb·ft).
16. Using the square hole in the crankshaft pulley, bar the engine over slowly, in a
counterclockwise direction, approximately 180 degrees until the bearing split line is even
with the cap and block joint face. Care must be taken not to bar the engine over too
far and damage the bearing tang.
17. Remove the bearing remover and installer assembly, J 36187.
18. Install the lower main bearing shell to be used, into the engine main bearing cap.
NOTE:
Thrust washers in the No. 6 main bearing cap are no longer required if the engine was
built with them. They do not need to be reinstalled.
19. Coat the threads and underside of the heads of the main bearing cap bolts with
International Compound #2®. Position the main bearing cap, with bearing(s) in place into
the saddle and install the bolts and washers. Rap the main bearing caps sharply with
a fiber mallet or plastic hammer to ensure the caps are fully seated. Torque the bolts
to 470-530 N·m (347-391 lb·ft).
20. It will be necessary to reinstall the upper and lower main bearing shells (and the
upper thrust washers for the No. 6 main) and the main bearing cap, for the bearings
being inspected or replaced before proceeding to the next main bearing saddle.
Refer to section 1.9.3.
21. Repeat this procedure for each main bearing saddle until all seven sets of main bearings
have been removed and inspected or replaced.
NOTE:
No. 7 main bearing journal does not have an oil hole, so the bearing remover cannot
be used at that position. The No. 7 upper main bearing should be removed with both
No. 6 and No. 7 main bearing caps off. Using a suitable tool, push on the No. 7 upper
bearing on the side opposite the tang and dislodge the bearing tang from the tang slot in
the cylinder block. Carefully push and pull the bearing the rest of the way out, taking
care not to damage the bearing shell. Rotate the crankshaft, and apply some pressure
to the side of the bearing while rotating.
22. After removal, clean the bearings.
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1.9.2.1
Cleaning of Main Bearings
Perform the following to clean the main bearing:
1. Immerse the bearing in cleaning agent.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
2. Blow dry the main bearings with compressed air and inspect for damage and wear.
Refer to section 1.9.2.2.
1.9.2.2
Inspection of Crankshaft Main Bearings
Bearing failures may result from deterioration (acid formation) or contamination of the oil or
loss of oil. An analysis of the lubricating oil may be required to determine if corrosive acid and
sulphur are present, which cause acid etching, flaking and pitting. Bearing seizure may be due
to low oil or no oil.
Inspect the bearings for scoring, pitting, flaking, etching; or signs of overheating. The bearing
overlay may develop minute cracks or small isolated cavities (checking) on the bearing surface
during normal engine operation. These are characteristics of and are not detrimental to this type of
bearing. They should not be replaced for these minor surface imperfections, since function of the
bearings is in no way impaired and they will give many additional hours of trouble-free operation.
Inspect the backs of the bearing shells for bright spots, which indicate they have been moving in
the bearing caps. If such spots are present, discard the bearing shells, and inspect the bearing caps
and upper bearing saddles.
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CRANKSHAFT MAIN BEARINGS
Measure the thickness of the bearing shells at a point, 90 degrees from the parting line.
See Figure 1-156.
Figure 1-156
Main Bearing Measurements
Tool J 4757, placed between the bearing shell and a micrometer, will give an accurate
measurement. The bearing shell thickness will be the total thickness of the steel ball in the tool
and the bearing shell, less the diameter of the ball. This is the only practical method for measuring
the bearing thickness, unless a special micrometer is available for this purpose. The minimum
thickness of a worn standard main bearing shell is 3.937 mm (0.155 in.). If any of the bearing
shells are thinner than this dimension, replace all of the bearing shells. A new standard bearing
shell has a thickness of 3.962-3.980 mm (0.1560 -0.1567 in.). If any bearing shell shows wear
through the overlay across the width of the shell, all bearing shells must be replaced.
In addition to the thickness measurement, check the clearance between the main bearings and the
crankshaft journals. This clearance may be determined with the crankshaft in place by means of a
soft plastic measuring strip that is squeezed between the journal and the bearing as described in
"Checking Bearing Clearance". Refer to section ADDITIONAL INFORMATION1.A. With the
crankshaft removed, measure the outside diameter of the crankshaft main bearing journals and the
inside diameter of the main bearing shells when installed in place with the proper torque 470-530
N·m (347-391 lb·ft) torque on the bearing cap bolts. When installed, the bearing shells are 0.0254
mm (0.001 in.) larger in diameter at the parting line than 90 degrees from the parting line.
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(Rev. 2004)
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The bearing shells do not form a true circle out of the engine. When installed, the bearing shells
have a squeeze fit in the main bearing bore and must be tight when the bearing cap is drawn down.
This crush assures a tight, uniform contact between the bearing shell and bearing seat. Bearing
shells that do not have sufficient crush will not have uniform contact, as shown by shiny spots on
the back, and must be replaced. If the clearance between any crankshaft journal and its bearing
shells exceeds 0.1524 mm (0.006 in.), all of the bearing shells must be discarded and replaced.
This clearance is 0.040-0.127 mm (0.0016 -0.005 in.) with new parts.
If installing new replacement bearings, it is very important to thoroughly inspect the crankshaft
journals. Also, damaged bearings may cause bending fatigue and resultant cracks in the
crankshaft. Refer to section 1.7.2.11, and refer to section 1.7.2.9.
Do not replace one main bearing shell alone. If one bearing shell requires replacement, install all
new upper and lower shells.
NOTE:
Anytime a new or reground crankshaft is used, all new bearing shells must be used.
Bearing shells are available in 0.254, 0.508 and 0.762 mm (approximately 0.010,.020 and
0.030 in.) undersize for service with reground crankshafts as listed in Table 1-12to determine
what size bearings are required. Ensure the correct bearing to journal clearance is maintained
when using these parts.
NOTE:
Bearing shells are NOT reworkable from one undersize to another undersize under
any circumstances.
Inspect the crankshaft thrust washers. If the washers are discolored or worn excessively, or if the
crankshaft end play is excessive, replace the thrust washers. Inspect the crankshaft thrust surfaces.
Refer to section 1.7.2.1. If, after dressing or regrinding the thrust surfaces, new standard size
thrust washers do not hold the crankshaft end play within the specified limits, it may be necessary
to install oversize thrust washers on one or both sides of the No. 6 main bearing. A new standard
size thrust washer is 3.56-3.48 mm (0.140 -0.137 in.) thick. Thrust washers are available in 0.127
and 0.254 mm (0.005 and 0.010 in.) oversize.
All information subject to change without notice.
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CRANKSHAFT MAIN BEARINGS
1.9.3
Installation of Main Bearings Shells (Crankshaft Removed)
Install the main bearing shells as follows:
1. Check that all of the parts are clean and dry.
2. Apply clean engine oil 360 around each crankshaft main journal and install the upper
main bearing shells to their respective saddles in the cylinder block. Note the locating
tangs and be sure the oil holes register with the galleries in the cylinder block.
3. Be sure to install the drilled bearing shells in the cylinder block and the plain bearing
shells in the bearing caps. The upper and lower main bearing shells are not alike; the
upper shell is drilled for lubrication, the lower bearing shell is not. If they are not installed
correctly, the oil flow to the bearings and to the upper end of the connecting rods will
be blocked off. Used bearing shells must be reinstalled on the same journal from which
they were removed.
4. Perform all of the steps under "Installation of Crankshaft." Refer to section 1.7.3.
[a]
Measure the main bearing clearances. Refer to section ADDITIONAL
INFORMATION1.A, "Checking Bearing Clearances" in "Shop Notes".
5. Measure the crankshaft end play. The minimum and maximum specifications are
listed in Table 1-23.
6. Toruqe all of the main bearing cap bolts to 470-530 N·m (347-391 lb·ft).
7. Measure the main bearing bores with dial bore gage, J 5347-B. The minimum
specifications are listed in Table 1-17.
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(Rev. 2004)
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1.10 GEAR CASE COVER
The gear case cover and gear case housing bolt together at the front of the engine to form a sealed
compartment for the engine gear train. See Figure 1-157.
Figure 1-157
Engine Gear Case and Cover
For Series 60 2002 engines with EGR sytems see Figure 1-158
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(Rev. 2004)
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1.10
GEAR CASE COVER
Figure 1-158
1-204
Engine Gear Case and Cover for Series 60 2002
(Rev. 2004)
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Figure 1-159
Gear Case Cover-mounted Components
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1.10
GEAR CASE COVER
The gear case cover also serves as a retainer for the crankshaft front oil seal. See Figure 1-160.
Figure 1-160
1-206
Crankshaft Front Oil Seal
(Rev. 2004)
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Several components that are mounted to the gear case cover include the water pump (pre-1991
engines only), accessory drive assembly, and fan support bracket See Figure 1-161.
Figure 1-161
Gear Case Cover-mounted Components
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1.10
GEAR CASE COVER
The front engine support is bolted to the front of the gear case cover, directly behind the crankshaft
pulley and vibration damper. See Figure 1-162and see Figure 1-163.
Figure 1-162
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Typical Front Engine Support
(Rev. 2004)
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1. Bracket, Engine Mounting
6. Screw, Isolator Mounting
2. Short Mounting Bracket
7. Washer
3. Front Heat Exchanger Support Mounting Bracket
8. Heat Exchanger Support
4. Long Mounting Bolt
9. Bracket, Rear Engine Mounting
5. Isolator, Heat Exchanger
Figure 1-163
Typical Front Engine Support Heat Exchanger-Cooled Pleasure
Craft Marine
Several access covers are provided on the gear case cover for service of the engine without
removing the gear case cover. Removal of the camshaft drive gear access cover will allow the
removal of the camshaft drive gear-to-camshaft bolt for camshaft and cylinder head removal
without removing the gear case cover. See Figure 1-164.
All information subject to change without notice.
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1.10
GEAR CASE COVER
Figure 1-164
Camshaft Drive Gear Access Cover
The fan support bracket includes the access cover for the adjustable idler gear. See Figure 1-165.
Figure 1-165
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Fan Support Bracket
(Rev. 2004)
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With the fan support bracket and the camshaft drive gear access cover removed, the gear lash
between the adjustable idler gear and the camshaft drive gear can be measured and adjusted
Refer to section 1.22.2.1.
On vehicles without power steering, an access cover is provided for inspection of the air
compressor drive gear. See Figure 1-166.
Figure 1-166
Air Compressor Drive Gear Access Cover
On some vehicles equipped with power steering, the power steering hydraulic pump is mounted
to the gear case cover in the place of the access cover, and is driven by a short coupling that fits in
the splined hole in the center of the air compressor drive gear. The pump is installed with a gasket.
All information subject to change without notice.
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1.10
1.10.1
GEAR CASE COVER
Repair or Replacement of Gear Case Cover
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-167.
Figure 1-167
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Flowchart for Repair or Replacement of Gear Case Cover
(Rev. 2004)
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1.10.2
Removal of Engine Gear Case Cover
With the engine mounted on an overhaul stand. Remove the gear case cover as follows:
NOTICE:
Do not hit the face of the damper to loosen it. Damage to the
internal components may result. The oil pan cannot be used to
support the front of the engine in a vehicle, as its thermoplastic
construction will not support the weight.
1. Drain the engine oil and remove the engine oil pan. Refer to section 13.13.1, for oil
draining and refer to section 3.11.2.
2. Loosen the fan hub mounting bolts. Loosen the fan adjusting bolt. Back the adjuster
off far enough to remove the drive belts. Remove the fan and fan hub assembly.
Refer to section 4.7.2.
3. Loosen the alternator mounting bolts. Remove the alternator drive belts, alternator, and
mounting brackets (if so equipped). Refer to section 8.2.2. See Figure 1-168.
Figure 1-168
Alternator and Related Parts
4. Loosen the air conditioner compressor and mounting brackets (if so equipped). Refer to
OEM guidelines.
All information subject to change without notice.
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1.10
GEAR CASE COVER
5. Remove the five fan support bolts. See Figure 1-169.
Figure 1-169
Fan Support Bolt Location
6. Remove the water pump assembly. Refer to section 4.3.2for front mounted water pump.
Refer to section 4.2.2 for gear case mounted.
7. Remove the power steering pump (if so equipped). Refer to OEM guidelines.
8. Remove the crankshaft pulley. Refer to section 1.13.2.
9. Remove the vibration damper. Refer to section 1.12.2.
10. Remove the front engine mount by removing the four bolts securing the front engine
mount to the gear case cover.
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11. Loosen and remove the five bolts that secure the accessory drive assembly to the gear case
cover. See Figure 1-170.
Figure 1-170
Accessory Drive Assembly
12. Remove the accessory drive assembly by pulling it straight out of the gear case cover to
avoid damaging the rubber O-ring. See Figure 1-170.
All information subject to change without notice.
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1.10
GEAR CASE COVER
13. There are a total of 34 bolts that secure the gear case cover to the gear case. Bolts 17, 18, 19
and 20 were removed with the front engine mount. Bolts F1 through F5 were removed in
a previous step; refer to step 12. Loosen and remove bolts 1 through 16, 21, 22 (see note).
Figure 1-171
Gear Case Cover Bolt Arrangement (Front)
NOTE:
Bolts 21 and 22 are rear bolts on pre-1991 engines.
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[a]
Remove the SRS. Refer to section 2.32.2.
[b]
Remove the air compressor drive assembly by removing the six bolts on the back of
the gear case on the intake side of the engine located around the air compressor drive
assembly. See Figure 1-172.
(Rev. 2004)
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Figure 1-172
[c]
Gear Case Cover Bolt Arrangement (Left Rear)
Remove the bolts on the back of the gear case on the water pump (right) side of
the engine. See Figure 1-173.
Figure 1-173
Gear Case Cover Bolt Arrangement (Right Rear)
For Series 60 2002 Engines remove gear case cover from gear case as follows:
All information subject to change without notice.
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1.10
GEAR CASE COVER
14. Remove Compact Gear Train Assembly. Refer to Section 1.23.
15. Remove 21 bolts securing Gear Case Cover from Gear case. See Figure 1-174
Figure 1-174
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Gear Case Cover Bolt Location
(Rev. 2004)
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16. Support the gear case cover with a suitable lifting device, using the front engine lift
bracket. See Figure 1-175.
1. Engine Lifter Bracket
3. Gear Case Housing
2. Gear Case Cover
Figure 1-175
Engine Gear Case Cover Support
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1.10
GEAR CASE COVER
NOTE:
There is a rubber O-ring installed between the center of the bull gear hub and the gear
case cover. The O-ring may adhere to the cover when it is removed. Be sure the O-ring
is not lost. See Figure 1-176.
Figure 1-176
Bull Gear O-ring
17. Tap the gear case cover with a fiber mallet or plastic hammer to loosen it from the gear
case. Remove the engine gear case cover.
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(Rev. 2004)
All information subject to change without notice.
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1.10.2.1
Inspection of Gear Case Cover
Inspect the gear case cover as follows:
1. Clean all of the old gasket sealer from the mating surfaces of the gear case and gear case
cover. Refer to General Information, "Cleaning".
2. Clean the gasket material from the mating surfaces of any components or access covers
that were removed from the gear case cover, and the gear case cover itself.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
3. Clean all of the removed parts except the electrical components with clean fuel oil and
dry with compressed air.
NOTE:
Any time the gear case cover is removed, the crankcase oil seal must be replaced.
Install the new front oil seal after the gear case cover has been installed to the engine.
4. If necessary, remove the crankshaft front oil seal at this time. Refer to section 1.8.2. Inspect
the gear case cover for stress cracks or breaks in the casting. Refer to section 1.10.2.1.
Repair or replace as necessary. Refer to section 1.11.3.
5. Inspect all O-rings for signs of dryness or splitting. Replace as necessary.
1.10.3
Installation of Gear Case Cover
Perform the following steps for gear case installation:
1. Apply a continuous 1/16 in. bead of Gasket Eliminator PT-7276 (Loctite® 518) or
equivalent to the mating surface of the gear case.
NOTE:
Gasket eliminator cures with the absence of air. The length of time between gear case
cover installation and torquing the bolts that secure the gear case cover to the gear
case should be kept to a minimum.
All information subject to change without notice.
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2. Install two guide studs, J 36107, to the gear case. See Figure 1-177.
1. Front Gear Case Cover
4. Locating Dowel (Round)
2. Front Engine Lift Bracket
5. Locating Dowel (Diamond)
3. Front Gear Case Housing
Figure 1-177
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Gear Case Cover Guide Stud Location
(Rev. 2004)
All information subject to change without notice.
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3. Support the gear case cover with a suitable lifting device, using the front engine lift
bracket. See Figure 1-175.
4. Position the gear case cover on the guide studs and slide it forward. Index the two dowels
in the gear case. See Figure 1-177.
5. For Series 60 2002 Engines there are 21 bolts that secure gear case cover to to gear
case. Torque bolts No.1 through 19 to 65 N·m (48 lb·ft). Torque bolts 20 and 21 to 113
N·m (83 lb·ft). See Figure 1-178.
Figure 1-178
Gear Case Cover Bolt Torque Sequence Series 60 2002 Engine
6. There are 34 bolts that secure the gear case cover to the gear case (including five for the
fan support bracket). Install them as follows:
All information subject to change without notice.
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NOTICE:
With gasketless parts such as the gear case cover; the torque
values and tightening sequences are critical to prevent parts
warpage.
[a]
Install the shorter bolts, No. 1 through 16, 21, 22 (see note), in various locations at
the front of the gear case cover. Finger-tighten them. Remove the guide studs when
installing bolts 7 and 14. See Figure 1-179.
NOTE:
Bolts 21 and 22 are rear bolts on pre-1991 engines.
Figure 1-179
[b]
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Gear Case Cover Bolt Torque Sequence (Front)
Torque bolts 1 through 16, 21, 22 (see note), to 58-73 N·m (43-54 lb·ft).
(Rev. 2004)
All information subject to change without notice.
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[c]
Install the front engine mount to the gear case cover. Install the four, longer, front
engine mount-to-gear case cover bolts, finger-tight.
[d]
Torque bolts 17, 18, 19 and 20 to 160-200 N·m (118-148 lb·ft). See Figure 1-179.
[e]
Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and
torque bolts F1, F2 and F3 to 58-73 N·m (43-54 lb·ft). Torque bolts F4 and F5 to
160-200 N·m (118-148 lb·ft).
[f]
Install the six bolts on the intake (left) side of the engine around the air
compressor drive. Torque the bolts to 58-73 N·m (43-54 lb·ft), using the sequence.
See Figure 1-180.
Figure 1-180
[g]
Air Compressor Drive Torque Sequence
Install the SRS to the gear case; refer to section 2.32.3.
All information subject to change without notice.
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[h]
Install the two rear mounted bolts (pre - 1991 engines only) bolts on the exhaust
(right) side of the engine. Torque the number 2 and 3 bolts to 58-73 N·m
(43-54 lb·ft) torque. See Figure 1-181.
Figure 1-181
Gear Case Cover Bolt Torque Sequence (Right Rear)
7. Install a new crankshaft front oil seal. Refer to section 1.8.7.
8. Install the accessory drive assembly to the gear case. Refer to section 1.29.5.
9. Install the vibration damper to the crankshaft. Refer to section 1.12.3.
10. Install the crankshaft pulley to the end of the crankshaft. Refer to section 1.13.3.
11. Install the water pump assembly. Refer to section 4.2.8for gear case mounted.
Refer to section 4.3.7 for front mounted.
12. Install a new gasket between the power steering pump cover and the gear case (if so
equipped).
13. Install the power steering pump cover to the gear case cover with the six bolts. Tighten the
bolts progressively in a star-shaped pattern to draw the power steering pump in evenly.
Torque the bolts to 30-38 N·m (22-28 lb·ft), using a star-shaped pattern.
14. Insert a new gasket between the camshaft drive gear access cover and the gear case cover.
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15. Install the camshaft drive gear access cover to the gear case cover. Torque the bolts to
30-38 N·m (22-28 lb·ft), using the tightening sequence. See Figure 1-182.
Figure 1-182
Access Cover Bolt Torque Sequences
16. Install the air conditioner compressor and brackets. Install the air conditioner compressor
drive belt. Refer to OEM guidelines.
17. Install the alternator and brackets. Refer to section 8.2.3. Install the alternator drive
belts. Refer to section 13.13.10.
18. Adjust the alternator and air conditioner compressor drive belts to the specifications.
Refer to section 13.13.10.
19. Install the engine oil pan. Refer to section 3.11.4. Fill the crankcase with recommended
lubricating oil. Refer to section 13.13.1.
All information subject to change without notice.
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1.10.4
Installation of Acoustical Gear Case Covers
Install acoustical covers as outlined below. See Figure 1-183, and see Figure 1-184, for Group
A installations with accessory drive. See Figure 1-185 and see Figure 1-186for installation on
Group B without accessory drive. See Figure 1-187 and see Figure 1-188for typical Group C
installations. See Figure 1-189and see Figure 1-190for Group D installations.
1. Using required fasteners, install front gear case acoustical cover and accessory drive
acoustical cover. Tighten bolts and nut(s) to the torque values: listed in Table 1-4.
2. Using required fasteners and clips, install right rear and left rear covers. Tighten bolts and
nut(s) to the torque values listed in Table 1-4.
Table 1-4
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Bolt or Nut Size
Required Torque
M6 x 1.0
13-16 N·m (10-12 lb·ft)
M8 x 1.25
30-38 N·m (22-28 lb·ft)
M10 x 1.5
58-73 N·m (43-54 lb·ft)
Acoustical Cover Fastener Torque Values
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
1. Nut
4. Acoustical Cover
2. Bolt
5. Gear Case
3. Acoustical Cover Clip
6. Gear Case Cover
Figure 1-183
Typical Group A Front Acoustical Cover Installation (With
Accessory Drive)
All information subject to change without notice.
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1. Gear Case Cover
5. Bolt
2. Gear Case
6. Acoustical Cover
3. Acoustical Cover Snap
7. Acoustical Cover
4. Acoustical Cover Clip
8. Nut
Figure 1-184
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Typical Group A Rear Acoustical Cover Installation (With
Accessory Drive)
(Rev. 2004)
All information subject to change without notice.
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1. Nut
4. Acoustical Cover
2. Bolt
5. Gear Case
3. Acoustical Cover Clip
6. Gear Case Cover
Figure 1-185
Typical Group B Front Acoustical Cover Installation (No
Accessory Drive)
All information subject to change without notice.
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GEAR CASE COVER
1. Gear Case Cover
5. Bolt
2. Gear Case
6. Acoustical Cover
3. Acoustical Cover Snap
7. Acoustical Cover
4. Acoustical Cover Clip
8. Nut
Figure 1-186
1-232
Typical Group B Rear Acoustical Cover Installation (No
Accessory Drive)
(Rev. 2004)
All information subject to change without notice.
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1. Nut
4. Acoustical Cover
2. Bolt
5. Gear Case
3. Acoustical Cover Clip
6. Gear Case Cover
Figure 1-187
Typical Group C Front Acoustical Cover Installation
All information subject to change without notice.
(Rev. 2004)
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1.10
GEAR CASE COVER
1. Gear Case Cover
5. Bolt
2. Gear Case
6. Acoustical Cover
3. Acoustical Cover Snap
7. Acoustical Cover
4. Acoustical Cover Clip
8. Nut
Figure 1-188
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Typical Group C Rear Acoustical Cover Installation
(Rev. 2004)
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1. Bolt
4. Acoustical Cover
2. Nut
5. Gear Case
3. Acoustical Cover Clip
6. Gear Case Cover
Figure 1-189
Typical Group D Front Acoustical Cover Installation
All information subject to change without notice.
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GEAR CASE COVER
1. Gear Case Cover
5. Bolt
2. Gear Case
6. Acoustical Cover
3. Acoustical Cover Snap
7. Acoustical Cover
4. Acoustical Cover Clip
8. Nut
Figure 1-190
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Typical Group D Rear Acoustical Cover Installation
(Rev. 2004)
All information subject to change without notice.
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1.11 GEAR CASE
The gear case housing is constructed of cast iron, with machined mating surfaces, and is bolted to
the front of the engine cylinder block. The gear case and gear case cover are bolted together to
provide a sealed compartment for the engine gear train. See Figure 1-191.
1. Lifting Bracket
3. Gear Case Housing
2. Gear Case Cover
Figure 1-191
Gear Case and Gear Case Cover
Several components are mounted to the gear case, including the adjustable idler gear assembly,
see Figure 1-194, the fuel pump drive assembly, see Figure 1-195, the air compressor drive
assembly or raw water pump drive assembly, see Figure 1-196; the water pump assembly (1991
and later engines) see Figure 1-197; and the camshaft thrust plate and drive gear assembly
see Figure 1-218.
All information subject to change without notice.
(Rev. 2004)
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In July 2001, new right and left side gear case stiffening brackets were added to provide: reduce
engine noise, increase belt driven accessory life, reduce gear case vibration amplitude and reduce
wear on the cam thrust plate perimeter seal. See Figure 1-192and see Figure 1-193.
Figure 1-192
Gear Case Stiffening Bracket (Left Side)
Figure 1-193
Gear Case Stiffening Bracket (Right Side)
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(Rev. 2004)
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1. Gear Case
5. Adjustable Idler Gear
2. Diamond Dowel
6. Adjustable Idler Hub
3. Adjustable Idler Gear Locknut (3)
7. Adjustable Idler Gear Stud (3)
4. Adjustable Idler Gear Hub, Retainer
8. Round Dowel
Figure 1-194
Adjustable Idler Gear Assembly
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1. Fuel Pump Drive Gear
5. Shaft and Bearing Assembly
2. Snap Ring
6. Fuel Pump Drive Hub
3. O-ring
7. Fuel Pump Drive Coupling
4. Fuel Pump Drive Housing
8. Fuel Pump Assembly
Figure 1-195
1-240
Fuel Pump Drive Assembly
(Rev. 2004)
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1. Drive Housing
8. Drive Hub Flange Nut
2. Washers
9. Drive Housing Long Bolt
3. Drive Housing Short Bolt
10. Drive Shaft
4. Drive Ball Bearing
11. Drive Gear
5. Snap Ring
12. Drive Gear Bolt
6. Spacer
13. Drive Housing Gasket
7. Drive Hub
14. Gear Case Housing
Figure 1-196
Air Compressor or Raw Water Pump Drive Assembly
All information subject to change without notice.
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GEAR CASE
1. Retaining Bolt
11. Oil Seal
2. Washer
12. Water Pump Housing O-ring
3. Water Pump Drive Gear
13. Drain Cock
4. Snap-ring
14. Water Pump Housing
5. Bearing Race
15. Water Pump Housing Pipe Plug
6. Bearing
16. Water Seal
7. Spacer Rings (2)
17. Impeller
8. Bearing
18. Water Pump Cover O-ring
9. Bearing Race
19. Water Pump Cover
10. Drive Shaft
20. Water Pump Cover Snap Ring
Figure 1-197
1-242
Water Pump Assembly
(Rev. 2004)
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
To eliminate the possibility of oil leakage at the adjustable idler gear stud location, Detroit Diesel
recommends the following:
When rebuilding a Series 60 engine, or if the gear case is removed for any reason, the three
original adjustable idler gear studs should be removed and replaced with new studs.
Before pressing studs into the gear case, coat the shanks and underside of the stud heads with
Loctite® No. 242 Sealant. This will prevent any oil leakage around the studs during engine
operation.
The Timing Reference Sensor (TRS) is an electronic component that is bolted to the side of the
gear case on the intake (left) side of the engine just above the oil pan. See Figure 1-198.
Figure 1-198
Timing Reference Sensor (TRS)
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The Synchronous Reference Sensor (SRS) is an electronic component that is bolted to the gear
case at the lower, intake (left) side of the engine. See Figure 1-199.
Figure 1-199
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Synchronous Reference Sensor
(Rev. 2004)
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An opening is provided in the center of the gear case, for the bull gear and camshaft idler gear
assembly, which bolts directly to the engine block. See Figure 1-200.
Figure 1-200
Bull Gear and Camshaft Idler Gear Assembly
All information subject to change without notice.
(Rev. 2004)
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GEAR CASE
An access cover is provided at the rear of the gear case on the cooler (right) side of the engine.
This access cover provides an opening for inspection of the accessory drive assembly drive
gear. See Figure 1-201.
NOTE:
This access cover opening may be cast closed on the rear of the gear case.
Figure 1-201
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Accessory Drive Gear Access Cover (Pre-1991 Engines)
(Rev. 2004)
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For gear lash measurement and adjustment procedures for the gears in the engine gear train,
Refer to section 1.22.2.1.
An oil gallery is drilled in the gear case casting, for lubrication of the adjustable idler gear
assembly. A hole in the front of the cylinder block, indexes with the gear case gallery. At the edge
of the gear case the gallery is threaded for insertion of a plug. An exit hole feeds the adjustable
idler gear assembly. See Figure 1-202.
NOTE:
Do not use the oil plug location for an oil supply or for checking oil pressure.
Figure 1-202
Adjustable Idler Gear Lubrication Gallery
All information subject to change without notice.
(Rev. 2004)
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GEAR CASE
Figure 1-203
Air Compressor Lubrication Gallery
For the Series 60 2002 Engine there is a drilled oil passage in the gear case casting for lubrication
of the air compressor. See Figure 1-203.
1-248
(Rev. 2004)
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1.11.1
Repair or Replacement of Gear Case
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-204.
Figure 1-204
Flowchart for Repair or Replacement of Gear Case
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GEAR CASE
1.11.2
Removal of Gear Case
Perform the following steps to remove the gear case:
1. Remove the SRS. Refer to section 2.32.2.
2. Remove the TRS. Refer to section 2.33.2.
3. Remove the rocker arm assemblies. Refer to section 1.3.2.
4. On heat exchanger-cooled marine engines, remove the water-cooled charge air cooler.
Refer to section 4.4.2. Or remove the heat exchanger tank. Refer to section 2.15.1.
5. Perform all of the steps for camshaft removal. Refer to section 1.24.2.
6. For Series 60 2002 Engine remove compact gear train assembly. Refer to section 1.23.
7. Remove the 3 bolts that secure the camshaft gear pilot tool, J 35906, to the gear case
and remove the tool.
8. Remove the three bolts securing the former right side gear case stiffening bracket, or two
bolts securing the current right side gear case stiffening bracket. See Figure 1-205.
Figure 1-205
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Gear Case Stiffening Bracket (Right Side)
(Rev. 2004)
All information subject to change without notice.
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9. Remove the three bolts securing the left side gear case stiffing bracket. See Figure 1-206
Figure 1-206
Gear Case Stiffening Bracket (Left Side)
10. Remove gear case cover. Refer to section 1.10.2, for step 1 through step 13. Supporting
the gear case cover with a suitable lifting device, but don't remove it.
11. Remove the fuel pump from the fuel pump drive assembly (or air compressor).
Refer to section 2.8.2.
12. Remove the air compressor. Refer to section 10.1.5.
13. Remove the air compressor drive assembly. Refer to section 10.3.2.
All information subject to change without notice.
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14. Install the crankshaft protector, J 35994, to the oil seal contact area of the crankshaft. This
will help to protect the crankshaft seal surface when removing the bull gear and camshaft
idler gear assembly. See Figure 1-207.
Figure 1-207
Crankshaft Protector Installation
15. Remove the bull gear and camshaft idler gear assembly from the engine.
Refer to section 1.27.2.
16. Remove the adjustable idler gear assembly from the gear case. Refer to section 1.26.2.
17. Using a plastic hammer or fiber mallet, tap the rear face of the camshaft thrust plate to
remove the thrust plate, camshaft drive gear hub and camshaft drive gear from the gear
case.
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(Rev. 2004)
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18. Remove the 12 bolts that secure the gear case to the engine block. See Figure 1-208
Figure 1-208
Gear Case Mounting Bolt Locations
For Series 60 2002 Engine remove bolts as follows:
All information subject to change without notice.
(Rev. 2004)
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GEAR CASE
19. Remove fourteen bolts that secure gear case to engine block. See Figure 1-209.
Figure 1-209
1-254
Gear Case Mounting Bolt Locations
(Rev. 2004)
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20. Using a leather or cloth-wrapped strap, support the gear case. See Figure 1-210. For
Series 60 2002 engines see Figure 1-211.
Figure 1-210
Gear Case Removal
All information subject to change without notice.
(Rev. 2004)
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GEAR CASE
Figure 1-211
Series 60 2002 Gear Case Removal
21. Use a rubber hammer or plastic mallet to loosen the gear case from the cylinder block
dowels.
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(Rev. 2004)
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1.11.2.1
Inspection of Gear Case
Clean all of the old gasket sealer from the mating surfaces of the gear case, gear case cover, and
engine block. Refer to "Gasket Eliminator Removal," in the "General Information" section at the
beginning of this manual. Clean the gasket material from the mating surfaces of any components
or access covers that were removed from the gear case cover or gear case. Clean all of the parts
with clean fuel oil and dry with compressed air. Remove the oil gallery plug at the edge of the
gear case. See Figure 1-202.
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
Use compressed air to ensure the oil gallery is completely free of blockage. If necessary, use a
wire brush to clean the gear case oil gallery.
Inspect the gear case for stress cracks, breaks, or other damage. Repair or replace as necessary.
Inspect the adjustable idler gear studs for signs of galling or scoring. Replace as necessary.
Inspect all the individual components as outlined under the appropriate section.
All information subject to change without notice.
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1.11.3
Installation of Gear Case
Use the following instructions for gear case installation:
1. Apply a thin film of gasket eliminator PT-7276 (Loctite® 518) or equivalent to the
cylinder block. See Figure 1-212. Carefully smooth the bead around the block-to-gear
case oil passage to avoid contamination.
NOTE:
The installation of Gasket Eliminator to the gear case-to-block mating surfaces at the top
of the block is critical. Excess gasket eliminator material can extrude into the oil passage
between the block and gear case, causing early failure of components. In addition, the
bull gear recess area MUST be cleaned of any and all foreign material after installation
of the gear case to the engine block.
Figure 1-212
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Gasket Eliminator Application
(Rev. 2004)
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2. Insert gear case alignment plug, J 35651, into the bull gear and camshaft idler gear hub
recess in the cylinder block. See Figure 1-213.
Figure 1-213
Gear Case Alignment Plug
All information subject to change without notice.
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GEAR CASE
3. Using a suitable lifting sling made of cloth or leather, position the bull gear and camshaft
idler gear opening of the gear case over the gear case alignment plug. Index the hole
in the gear case mating surface with the diamond dowel at the lower left corner of the
cylinder block. See Figure 1-214.
Figure 1-214
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Cylinder Block Locating Diamond Dowel
(Rev. 2004)
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4. With the gear case alignment plug fully seated, the gear case centered on the alignment
plug and the diamond dowel in the cylinder block indexed with its mating hole in the gear
case, the gear case is positioned properly for bolt installation. See Figure 1-215.
Figure 1-215
Gear Case Positioning
NOTE:
Gasket Eliminator cures with the absence of air. The time between the installation of
the gear case, and torquing of the bolts that secure the gear case to the cylinder block
should be kept to a minimum.
All information subject to change without notice.
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GEAR CASE
5. Install the 12 gear case-to-cylinder block retaining bolts, finger-tight.
6. Torque the gear case-to-cylinder block bolts to 58-73 N·m (43-54 lb·ft). See Figure 1-216.
Figure 1-216
Gear Case Housing Bolt Torque Sequence
For Series 60 2002 Engine install gear case as follows:
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7. There are 14 bolts that secure the gear case to engine block. For bolt torque and torque
sequence see Figure 1-217.
Figure 1-217
Gear Case Torque Sequence for Series 60 2002 Engine
8. Remove the gear case alignment plug from the gear case.
9. Install the air compressor. Refer to section 10.1.8.
10. Install the air compressor drive assembly. Refer to section 10.3.6.
11. Install the fuel pump drive assembly to the gear case, if so equipped. Refer to section 2.8.5
or refer to section 2.8.6.
12. Install the fuel pump to the fuel pump drive assembly (or air compressor). Refer to section
2.9.3.
NOTE:
For 1991 and later model year engines, refer to section 4.2.8or refer to section 4.3.7 and
install the water pump assembly.
All information subject to change without notice.
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13. Lubricate the rubber O-ring on the camshaft thrust plate with clean engine oil. Install the
camshaft thrust plate assembly, with the camshaft drive gear and hub in place to the gear
case, using a plastic hammer or fiber mallet to tap the thrust plate rearward in the gear case
just enough to start it in the gear case. See Figure 1-218.
Figure 1-218
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Camshaft Thrust Plate Installation
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All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
14. Install the adjustable idler gear assembly to the gear case. Refer to section 1.26.3. Align
the timing marks of the adjustable idler gear and camshaft drive gear. See Figure 1-219.
1. Camshaft Idler Gear
4. Bull Gear
2. Adjustable Idler Gear
5. Crankshaft Timing Gear
3. Camshaft Drive Gear
Figure 1-219
Engine Gear Train Timing Marks
15. Inspect the bull gear and camshaft idler gear access opening in the gear case and remove
any foreign material.
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16. Install two bull gear guide studs, J 35785 to the cylinder block. See Figure 1-220.
Figure 1-220
Bull Gear Guide Stud Installation
NOTICE:
Always install crankshaft protector when installing the bull gear
and camshaft idler gear assembly to prevent damaging the
crankshaft oil seal contact surface.
17. Install the crankshaft protector, J 35994 to the oil seal contact area of the crankshaft. This
will help to protect the crankshaft seal surface when installing the bull gear and camshaft
idler gear assembly.
18. Install the bull gear and camshaft idler gear assembly to the guide studs. Align the timing
marks on the bull gear and the crankshaft timing gear and the camshaft idler gear and
adjustable idler gear; see Figure 1-219, and slide the bull gear and camshaft idler gear
assembly forward to seat it in the recess in the gear case and cylinder block.
19. Working through the lightening holes in the bull gear, install two of the bull gear assembly
mounting bolts through the hub and into the cylinder block. Finger-tighten the bolts.
20. Remove the two bull gear guide studs. Install the remaining two bull gear assembly
mounting bolts. Torque the bolts to 101-126 N·m (75-93 lb·ft). Tighten in a clockwise
sequence.
21. Check the timing marks on the gears to ensure the gear train is properly timed.
See Figure 1-219.
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22. Perform the following:
[a]
For crankshaft timing gear-to-oil pump gear lash measurement. Perform step 2,
refer to section 1.22.2.1.
[b]
For crankshaft timing gear-to bull gear lash measurement. Perform step 3,
refer to section 1.22.2.1.
[c]
To install the gear case cover. Refer to section 1.10.3.
[d]
Install the two bolts and nuts securing the left side gear case stiffening bracket to the
gear case. Torque to 75–81 N·m (55–60) lb·ft). See Figure 1-221
Figure 1-221
Gear Case Stiffening Bracket (Left Side)
[e]
Install the bolt securing the left side gear case stiffening bracket to the cylinder head.
Torque to 58–73 N·m (43–54 lb·ft). See Figure 1-221
[f]
Install the bolt securing the right side gear case stiffening bracket to the gear case.
Torque the former bracket bolt to 58–73 N·m (43–54 lb·ft) or torque the current gear
case bracket bolt to 74–81 N·m (53–60 lb·ft). See Figure 1-222
NOTE:
Bolts attaching bracket to the gear case are torqued first, then the bolt to cylinder head is
torqued next.
[g]
Install the two bolts securing the former right side gear case stiffening bracket to the
cylinder head or one bolt securing the current right side bracket. Torque the former
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bracket bolts to 58–73 N·m (43–54 lb·ft) or torque the current gear case bracket bolt
to 74–81 N·m (53–60 lb·ft). See Figure 1-222
Figure 1-222
Gear Case Stiffening Bracket (Right Side)
23. Refer to section 1.24.5, "Installation of Camshaft Bearing" and perform the necessary
steps.
24. For bull gear-to-accessory drive gear lash measurement, perform step
11. Refer to section 1.22.2.1.
25. Continue engine assembly.
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1.12 CRANKSHAFT VIBRATION DAMPER
A viscous type vibration damper is mounted on the front end of the crankshaft to reduce torsional
vibrations to a safe value. See Figure 1-223.
Figure 1-223
Viscous Vibration Damper Mounting with Crankshaft Pulley or
Crankshaft Pulley and Hub Assembly with Spindle
Prior to April 1993, 11.1 liter engines with less than 320 hp (238 kW